C__WHEELALIGNER_CCDWA - OM Ver.1.2.pdf

COMPUTERISED CCD WHEEL ALIGNER

OPERATING MANUAL (Ver.1.2)

Dear Customer, Congratulations, for selecting Computerised Wheel aligner as your Wheel alignment computer.

Our Wheel aligners are user friendly system which can be used effectively to correct all the

alignment angles of four wheelers.

We take special care to ensure that every Wheel aligner leaving our Factory is in the best

operating condition. This OPERATING MANUAL has been prepared to help you in getting the

best performance out of the equipment. Still, if you have any doubt, please do not hesitate to

contact us.

Read the Operating manual carefully before starting to use the equipment

Every attempt is made in this manual to guide the User on the effective use of the

Equipment. Any suggestion may please be sent to us for improvement.

INDEX

Page No.

1. WARRANTY – STATUTORY CLAUSE 1

2. SAFETY 2

2.1. INTENDED USE 2

2.2. SAFETY INSTRUCTIONS FOR COMMISSIONING 2

2.3. SAFETY INSTRUCTIONS FOR OPERATION 3

2.4. SAFETY INSTRUCTIONS FOR SERVICING 3

2.5. SAFETY FEATURES 4 2.5.1. POWER FAILURE DATA RECOVERY 4 2.5.2. CONTROL FUSES 4

2.6. SAFETY LABEL INFORMATION 4

3. FEATURES & SPECIFICATIONS 5

4. INSTALLATION 7

4.1. INSTALLATION REQUIREMENTS 7

4.2. LOCATION 7

4.3. SPACE REQUIREMENTS 7 4.3.1. ALIGNMENT PIT DIMENSIONS 7 4.3.2. ALIGNMENT LIFT DIMENSIONS 10

4.4. POWER REQUIREMENT 11

5. WHEEL ALIGNMENT PARAMETERS 12

5.1. CAMBER 12

5.2. TOE 14

5.3. CASTER 15

5.4. KINGPIN INCLINATION (Steering axis inclination) 16

5.5. THRUST ANGLE 17

5.6. FRONT WHEEL SETBACK 18

5.7. REAR WHEEL SETBACK 19

5.8. WHEEL RUNOUT 20

5.9. INCLUDED ANGLE 21

5.10. TRACK WIDTH DIFFERENCE 22

5.11. LOCK ANGLE 23

5.12. TOE OUT ON TURNS 24

6. DESCRIPTION OF MAIN PARTS 25

6.1. MAIN CABINET 26

6.2. DESKTOP COMPUTER (refer scope of supply) 26

6.3. INTERFACE BOX 26

6.4. DISPLAY UNIT (refer scope of supply) 27

6.5. RF TRANSCEIVER UNIT 28

6.6. SENSOR ARMS 28

6.7. ARM RESTING BRACKETS 30

6.8. KEYBOARD (refer scope of supply) 30

6.9. MOUSE (refer scope of supply) 30

6.10. STANDARD ACCESSORIES 31 6.10.1. WHEEL BRACKET 31 6.10.2. LCV ROTARY PLATE - 2 ton (Applicable only for LCV models) 32 6.10.3. LCV BRAKE PEDAL LOCK 32 6.10.4. STEERING LOCK 32 6.10.5. DATA MANAGER SOFTWARE 33

6.11. OPTIONAL ACCESSORIES 33 6.11.1. MECHANICAL ROTARY PLATE WITH ANGLE INDICATOR 33 6.11.2. WHEEL BRACKET EXTENSION ADAPTER 33 6.11.3. FOUR SHAFT CALIBRATION KIT 34 6.11.4. SINGLE SHAFT CALIBRATION KIT 34 6.11.5. RIM LOCKING PIN (HCV) 34 6.11.6. RIM LOCKING PIN (suitable for Run flat tyre rims) 34 6.11.7. RIM LOCKING PIN (suitable for Steel rims with fancy disc) 34 6.11.8. REAR WHEEL SLIDER 35 6.11.9. LONGER REAR WHEEL SLIDER 35 6.11.10. SENSOR ARM CABLE KIT 35 6.11.11. PRINTER (refer scope of supply) 35 6.11.12. MULTIMEDIA SPEAKER (refer scope of supply) 36 6.11.13. INTERNATIONAL VEHICLE DATA (refer scope of supply) 36

7. OPERATION 37

7.1. DEFECTS / MALFUNCTIONS 37

7.2. PRELIMINARY ALIGNMENT PREPARATION 37 7.2.1. ALIGNMENT USING ALIGNMENT PIT 38 7.2.2. ALIGNMENT USING ALIGNMENT LIFT 38

7.3. MAIN MENU 39

7.4. ALIGNMENT 41 7.4.1. VEHICLE SELECTION 42 7.4.2. VEHICLE INSPECTION 44 7.4.3. WHEEL RUNOUT 46 7.4.3.1 PUSH-PULL RUNOUT METHOD (applicable only for PPR models) 47 7.4.3.2 FOUR POINT RUNOUT METHOD 49 7.4.4. CASTER & KINGPIN SWING 50 7.4.4.1 ARMS HORIZONTAL 50 7.4.4.2 TOE OUT ON TURNS & LOCK ANGLE MEASUREMENT 51 7.4.4.3 TURN LEFT 52 7.4.4.4 TURN RIGHT 52 7.4.4.5 STRAIGHT AHEAD 52 7.4.5. ALIGNMENT PARAMETERS & RESULTS 54 7.4.5.1 REAR WHEEL PARAMETERS 55 7.4.5.2 FRONT WHEEL PARAMETERS 57 7.4.5.3 RESULTS 60 7.4.5.4 ADJUSTMENT TYPES 61

7.5. QUICK WHEEL ALIGNMENT 67

7.6. DATA MANAGER 68 7.6.1. DATE BASED ALIGNMENT REPORT 68 7.6.2. REGISTRATION NUMBER BASED ALIGNMENT REPORT 70 7.6.3. YEAR BASED ALIGNMENT REPORT 71 7.6.4. TECHNICIAN BASED ALIGNMENT REPORT 72 7.6.5. CUSTOMER DATABASE 72 7.6.6. REMINDER TO CUSTOMER 73

7.7. SETTINGS 74 7.7.1. VEHICLE SPECIFICATIONS 75 7.7.1.1 EUROPEAN / BRAZILIAN / UNITED STATES VEHICLE DATA 75 7.7.1.2 INDIAN VEHICLE DATA 75 7.7.1.3 USER DEFINED VEHICLE DATA 76 7.7.2. MEASUREMENT UNITS 78 7.7.3. RESTORE CALIBRATION DATA 78 7.7.3.1 BACKUP CALIB DATA FROM PC TO SENSOR ARM 79 7.7.3.2 RESTORE CALIB DATA FROM SENSOR ARM TO PC 79 7.7.3.3 RESTORE FACTORY CALIBRATION DATA TO PC 79 7.7.3.4 BACKUP CALIB DATA FROM PC TO OTHER LOCATION/DEVICE 80 7.7.3.5 RESTORE CALIB DATA FROM OTHER LOCATION/DEVICE TO PC 80 7.7.4. WORKSHOP INFORMATION 80 7.7.5. PASSWORDS 80 7.7.5.1 SETTINGS PASSWORD 81 7.7.5.2 VEHICLE DATA PASSWORD 81 7.7.5.3 ELECTRONIC TURN TABLE (ERP) PASSWORD 83 7.7.5.4 RAPID / PUSH-PULL RUNOUT (PPR) PASSWORD 83 7.7.5.5 MECHANICAL TURN TABLE (with Angle indicator) PASSWORD 83 7.7.6. CALIBRATION HISTORY 84 7.7.7. USER LOGIN 84 7.7.8. ARM COMMUNICATION CHECK 84 7.7.9. RESET JOB NUMBER 85 7.7.10. TESTING OPTIONS 85 7.7.10.1 KEYPAD TESTING 85 7.7.10.2 BUZZER TESTING 86

7.8. LANGUAGE SETTINGS 86

8. MAINTENANCE 87

9. TROUBLE SHOOTING 88

9.1. HARDWARE TROUBLE SHOOTING 88

9.2. SOFTWARE TROUBLE SHOOTING 92

9.3. SELF DIAGNOSIS 93

9.4. MIS-ALIGNMENT TROUBLE SHOOTING 94

Ref.: CCDWA - OM 1

1. WARRANTY – STATUTORY CLAUSE The equipment is provided with Warranty for one year from the date of installation or thirteen months from the date of despatch whichever is earlier, against any manufacturing defect. The Warranty is subjected to the following conditions:

1. Ensure that proper power supply with protective Earthing is provided to the equipment. Any high voltage may damage the components, leading to system failure or electrical hazards. Power supply : Single Phase, 230V AC ± 10%, 50 Hz + N + PE (N - Neutral, PE - Protective Earth) Warranty ceases if this condition is not satisfied

2. Power supply to the equipment should be connected only through an UPS of minimum 1KVA capacity with AVR (Automatic Voltage Regulator) circuit. The system must be shut down before the UPS power trip OFF. Failing to comply may lead to software corruption. Warranty ceases if this condition is not satisfied

3. Do not attempt to open or service the equipment under any circumstances. Risk of electric shock may happen. Only Authorised / qualified service personnel should trouble shoot the equipment. Warranty ceases if the equipment is opened/tampered or serviced by un-authorised personnel

4. Warranty ceases if this equipment is used for any purpose other than intended use.

5. The equipment must be installed Indoor away from Sunlight, rain / moist areas Warranty ceases if the equipment is exposed to Sunlight, Rain / Water

6. Do not attempt to load any other Application software (Audio, Video etc.) under any circumstances, other than the alignment program loaded in the Factory. Warranty ceases if the system is loaded with any other Application software

7. If transportation, lifting, unpacking, installation, assembly, start up, testing, repair and maintenance have been performed by un-authorised personnel, the manufacturer shall not be responsible for injury to personnel or damage to objects.

8. DO NOT remove or modify any parts of the equipment as this could compromise the equipment's intended use. For any modifications / repairs consult the Manufacturer.

9. The Vehicle specification data must be entered by End user only. MANUFACTURER IS NOT RESPONSIBLE FOR ANY INCORRECT OR INCOMPLETE VEHICLE SPECIFICATIONS ENTERED INTO THE SYSTEM. No claim is entertained for any damage or loss.

10. Follow the Alignment lift manufacturer‟s safety recommendations when lifting a vehicle. MANUFACTURER IS NOT LIABLE FOR ANY DAMAGES CAUSED due to non-compliance

11. Make the warranty registration by duly signing the counterfoil of the Warranty card sent along with the equipment.

The Rechargeable batteries are provided with Warranty for six months from the date of installation or seven months from the date of despatch only whichever is earlier, against any manufacturing defect. It is the responsibility of End-user in handing over scrap batteries to Authorised collection centres for safe disposal in order to comply with the Battery (M&H) rules of National regulatory authority

MANUFACTURER does not warrant third party products / software added to our Wheel aligner through our Factory integration system. The below listed Third party products / peripherals / software are covered under the warranties provided by the respective OEM. Third party manufacturer's warranty may vary from product to product. Consult the respective product documentation for warranty information: 1. Desktop computer with Monitor 2. Printer 3. Keyboard 4. Mouse 5. Multimedia speakers 6. Operating system software

Ref.: CCDWA - OM 2

2. SAFETY

Thoroughly read all Safety labels and Manual instructions before installing, operating and maintaining the Wheel aligner. They are provided to remind the operator to exercise extreme care while performing wheel alignment with this product to prevent personal injury and property damage. Replace any label unreadable or missing on the Wheel aligner. Refer Part No. given for each Label for ordering.

It is the Operator‟s responsibility to have sufficient knowledge on the vehicle to be aligned and to use proper service methods and perform wheel alignment in an appropriate and acceptable manner that does not endanger safety of the Operator / others in the work area or the equipment or vehicle being serviced.

Always keep the Manual in a prominent place for quick reference.

Injury to personnel and damage to property incurred due to non-compliance with these safety instructions are not covered by the product liability regulations.

SYMBOLS

Failure to comply with instructions could result in personal injury

Failure to comply with instructions could result in property damage

Important information

2.1. INTENDED USE Use the Aligner as described in this Operating manual only.

Use only the Accessories recommended by the manufacturer.

Carryout alignment by positioning the vehicle to be aligned on the Alignment pit / Alignment lift only.

2.2. SAFETY INSTRUCTIONS FOR COMMISSIONING 1. Only Authorised service personnel are allowed to install and commission the

Wheel aligner.

2. Aligner should not be installed outdoors or in moist rooms (nearer to car washing).

3. To reduce the risk of fire, the equipment should not be installed at hazardous locations or in the vicinity of explosives or flammable liquids.

4. The Aligner should be installed with adequate ventilation in case of working on vehicles with internal combustion engines.

5. Keep the System away from high capacity Transformers, Electric motors and other strong magnetic fields.

6. Use proper handling tools while installation of Aligner for safety of equipment.

7. The electrical main supply to the Aligner must be connected through a CE certified Two pole, Type C, 6A MCB (Miniature Circuit Breaker). Proper Earthing must be provided.

8. If an Extension power cord is required, a cord with correct rating equal to or more than that of the equipment should be used.

9. Care should be taken to route the Power mains cord properly so that it is not tipped over or pulled.

10. During installation of Third party products (like Desktop computer, Monitor, Printer, Keyboard, Mouse, Speakers, Operating system software etc.) follow the safety instructions provided in the respective OEM's Installation document.

11. Ensure the disposal of ecologically harmful substances in accordance with the appropriate regulations.

Ref.: CCDWA - OM 3

2.3. SAFETY INSTRUCTIONS FOR OPERATION 1. Read the Operating manual thoroughly.

2. Only permit qualified personnel to operate, maintain or service the Aligner.

3. The operator should have thorough understanding of the vehicle systems being serviced & sufficient knowledge on the operation and safety features of alignment.

4. Always keep the Aligner and the surrounding work area clean and free of Tools, Parts, Debris and Grease etc.

5. Do not operate, if the equipment has been dropped or damaged until it has been examined by qualified service personnel.

6. Do not operate the equipment with damaged / twisted power cord.

7. Do not operate the equipment under direct sunlight. Even reflected sunlight reaching the camera will result in erratic readings and the system will display error indication.

8. Let the equipment to cool down completely before putting away.

9. Do not switch OFF the Main system switch, in order to charge the Sensor arms continuously. The Power panel switch located at the rear side of Main cabinet may be used to switch off the Processor unit alone.

10. Handle the Sensor arms carefully. Rough handling / shocks may cause damage to the Sensor and optical components.

11. Do not move or turn the equipment while the System is in power up condition.

12. Ensure the Rotary plates are locked with Locking pins before parking the vehicle.

13. Do not keep heavy objects over the equipment.

14. Do not hammer or hit any part of the equipment with Tools when the equipment is in ON condition.

15. Ensure the cables are not in contact with Rotary plates / moving parts / vehicle tyre.

16. Keep hair, loose clothing, fingers & all parts of body away from rotating / moving parts.

17. Always wear Eye Safety glasses while doing under chassis adjustments / corrections from the Alignment pit or Alignment lift to avoid oil drops / dust particles falling on to Eye. Use hand Gloves to avoid fire hazards from the hot surfaces of vehicle.

18. Always comply with the applicable accident prevention regulations.

2.4. SAFETY INSTRUCTIONS FOR SERVICING 1. Inspect the Wheel aligner on daily basis.

2. Only authorized personnel are allowed to service the Aligner.

3. Turn OFF MCB and unplug the Aligner before doing any maintenance or repair work.

4. Only certified engineers are allowed to service the parts of the equipment.

5. Do not remove / disable / override any safety device / assemblies.

6. Third party products should be serviced only by the OEM's authorised service personnel. Refer the respective service policies provided.

7. The use of cleaning agents which attack coating or sealing materials could result in equipment damage.

8. Use Manufacturer spare parts only to guarantee the reliable function and to ensure safety of the equipment.

Ref.: CCDWA - OM 4

2.5. SAFETY FEATURES

2.5.1. POWER FAILURE DATA RECOVERY During alignment, if the power goes off, the system has the facility to resume the previous job without redoing the entire alignment again.

When the power resumes after Power failure, the system will prompt the following message "Resume Old Job". If the previous job need to be continued, press YES to continue with the old job or else, press NO to start a new job.

2.5.2. CONTROL FUSES Control fuses (F1 & F2) are incorporated in the Main processing circuit and Sensor arms to protect the electronic components against high current. The Fuse holders are mounted on the Power panel and Sensor arm cabinets which can be easily accessed from outside for replacing the blown fuse. Always replace the Control fuse with same type and rating of CE marked Fuse.

2.6. SAFETY LABEL INFORMATION

Use only the charging facility available in the systemKeep the Battery/Charging contacts away from metal objectsNever heat the Battery or throw into fire

CAUTIONIt is the responsibility of End-User to comply with the Battery (M&H) rules of National regulatory authority and hand over scrap batteries to the Authorised collection centres

ATTENTION

Battery caution indicator (Part No. B2059)

230V AC ± 10%,

50 Hz

CAUTION

Input supply indicator (Part No. B2126)

WARNING

NO USER SERVICEABLE PARTS INSIDE.REFER TO QUALIFIED SERVICE PERSONNEL.

Electrical safety indicator (Part No. B0807)

WARNING

DISCONNECT POWER BEFORE

REMOVING COVER

Electrical safety indicator (Part No. B0808)

Sticker, Connection details (Part No. B8034)

Ref.: CCDWA - OM 5

3. FEATURES & SPECIFICATIONS

Sl. No.

Description Rpac

Premium

Rpac Premium

Plus

I Features

1 Simultaneous 4 wheel alignment using 4 Measuring heads

2 Suitable for LCVs of 12" – 24" Wheel size

3 Windows based alignment program

4 Robust wireless communication in the 2.4 Ghz unlicensed ISM band

5 No external antenna required (Internal antenna only)

6 Covers 100 meters of distance (Line of sight)

7 Field programmable 15 RF channels

8 On-line correction facility for Camber, Caster, Toe & Thrust angle

9 Automatic tracking of Left & Right turns for Caster & Kingpin measurement

10 Push-Pull Runout compensation (without jacking up the vehicle) *

11 Redo Runout option at the final stage of alignment

12 Display of Live Setback and Thrust angle reading

13 Setback and Thrust angle compensation

14 Display of Front & Rear Total Toe readings

15 Excess toe indication

16 Measurement of Rear wheel setback NA

17 Measurement of difference in Track width NA

18 Electronic On-line arms leveling (Front)

19 Toggle option for Front & Rear alignment

20 Battery powered Sensor arms with Auto-charging facility in idle condition

21 Included angle in printout

22 Customer address in printout

23 Customer data edit option provided before taking printout

24 Printout of Sensor calibration values

25 Export option for Data manager reports

26 Option for selection of Vehicle specifications during alignment

27 Power failure data protection

28 Save & proceed option (CTRL+S) during UPS power condition

29 Software upgradation through CD drive

30 TFT color display

II Special features

1 Sensor arms with unique design to work independently either in RF / Cable

2 Facility for enabling the optional features in the field itself

3 Data manager software for storing alignment results

4 Animated pictorial representation of all angles during alignment

5 Two color bar display for adjustment of all angles (Red/Green)**

6 Two color printout for indicating alignment condition (Red/Green)**

7 Unlimited databank of Indian / international vehicle specifications

8 Multi-lingual program

8 Selectable functions Quick wheel alignment program

Adjustment of Camber in wheel raised position

Spoiler program

Display of Toe in "mm" / "degree"

Measurement of Toe curve

Four point Runout compensation in single rotation

3D pictorial printout of alignment angles

Ref.: CCDWA - OM 6

Sl. No.

Description Rpac

Premium

Rpac Premium

Plus

III Optional features

1 International Vehicle data update (Refer scope of supply)

2 Voice prompts in English for operator guidance

3 Measurement of Lock Angle and Toe Out on Turns

4 Simultaneous auto-charging facility while the particular Sensor arm is operated using Cable

IV Technical specifications

Measurement parameters Range Accuracy

1 Front & Rear Camber ± 10° 00' ± 00° 02'

2 Caster ± 20° 00' ± 00° 05'

3 Kingpin ± 20° 00' ± 00° 05'

4 Front / Rear Toe ± 05° 00' ± 00° 02'

5 Total Toe ± 10° 00' ± 00° 04'

6 Front Wheel setback ± 05° 00' ± 00° 02'

7 Rear Wheel setback ± 05° 00' ± 00° 02' NA

8 Thrust angle ± 05° 00' ± 00° 02'

9 Front / Rear Runout ± 10° 00' ± 00° 02'

10 Included angle ± 30° 00' ± 00° 05'

11 Track width difference ± 02° 00' ± 00° 04' NA

12 Lock angle (Optional) ± 60° 00' ± 00° 20'

13 Toe Out on Turns (Optional) ± 60° 00' ± 00° 20'

V Electrical specifications

1 Power supply : Stabilised UPS (AVR Built-in) 230VAC ±10%, Single phase, 50Hz, +N +PE

2 Power consumption 200W 200W

3 Battery : 7.2 AH, 6V x 1 Valve Regulated Lead Acid

4 Battery backup time >12 hr. >12 hr.

5

Control fuse rating a) 3A, dia 5 mm x 20 mm, Slow blow type glass fuse (F1) b) 5A, dia 6.35 mm x 31.8 mm , Slow blow type Glass fuse (F2) c) 1A, dia 5 mm x 20 mm, Slow blow type glass fuse

VI General specifications

1 Operating temperature : 0° C to +50° C

2 Humidity : RH below 90%

3 Machine dimension – Unpacked (WxDxH) in mm (With Monitor) 1130x630x1450

4 Machine dimension – Packed (WxDxH) in mm (Without Monitor) 1) 780x695x1170 2) 770x420x1175

5 Machine weight – Unpacked 150 kg

6 Machine weight – Packed 200 kg

7 Desktop computer console dimensions (WxDxH) in mm (max.) 200x500x450

NOTE : * - Applicable for PPR models only ** - Red - Out of specification range Green - Within specification range

Ref.: CCDWA - OM 7

4. INSTALLATION

4.1. INSTALLATION REQUIREMENTS Wheel aligner installation should be done only by qualified Service personnel.

Provision of handling means such as Forklifts etc. is the owner's responsibility

4.2. LOCATION The Wheel aligner should not be installed outdoors, in moist rooms, at hazardous locations, or in the vicinity of explosives or flammable liquids.

The location should have adequate ventilation in case of working on vehicles with internal combustion engines.

Choice of a suitable location is the owner's responsibility

4.3. SPACE REQUIREMENTS Installation area should have roof.

Floor should be of good concrete flooring and should be leveled surface.

Proof of safe floor load capacity is the owner's responsibility

The clearances from side walls and roof should be adequate for the operator to move around and perform wheel alignment / maintenance.

Alignment can be carried out either on Alignment pit or using Alignment lift.

Choice of suitable alignment platform is the owner's responsibility

4.3.1. ALIGNMENT PIT DIMENSIONS Pit for Rotary plates and Rear wheel sliders (Optional) are necessary to carry out alignment. Both the pits should be in the same plane. However the main pit is intended only for the operator to go underneath the vehicle easily and carryout the required corrections. The length of the main pit can be made depending upon the availability of space. The Rotary plate / Slider plate locating pit can be finished with Granite or Marble purely by owner's choice.

Slider & its pit are not necessary for Heavy Commercial Vehicles (HCV). However alignment pit with provision for Slider placement can be used for alignment of Light Commercial Vehicle (LCV) using the same pit

Choice of finish of pit is the owner's responsibility

A Rail using MS flat (50 mm x12 mm) for Trolley should be partly embedded on the edge of main pit with specified height from floor level. This is required for placing the Jack over the moving trolley platform to lift the vehicle while carrying out Runout. A centralised single Hydraulic jack or Dual pneumatic jack is recommended.

The floor level between the Left and Right rotary plate pits should be same. The area adjoining the Main pit (except Rotary plate & Slider pits) should be maintained at even level.

The surface over which Rotary Plates are kept must be perfectly leveled using Spirit level. Also, perfect leveling must be ensured on both the sides of pit. Otherwise it will affect the alignment results.

Ref.: CCDWA - OM 8

PIT DIMENSIONS – Maximum Wheel base – 3.2 metre

Fig. 1

Ref.: CCDWA - OM 9

PIT DIMENSIONS – Maximum Wheel base – 4 metre

# #

#

Fig. 2

Ref.: CCDWA - OM 10

4.3.2. ALIGNMENT LIFT DIMENSIONS SCISSOR LIFT DIMENSIONS – Maximum Wheel base – 4 metre

Fig. 3

Ref.: CCDWA - OM 11

FOUR POST LIFT DIMENSIONS – Maximum Wheel base – 4 metre

Fig. 4

4.4. POWER REQUIREMENT Stabilised UPS 230V AC ± 10%, Single Phase, 50 Hz + N + PE

The supply to the Wheel aligner must be connected through an UPS of minimum 1KVA capacity with AVR circuit using a CE certified Two Pole, Type C, 6A MCB. Proper Earthing must be provided. Also ensure that Live phase is on the right side point of the wall socket.

Neutral to Line Voltage should be 230V AC ± 10% Line to Earth voltage should be 230V AC ±10% Neutral to Earth leakage should be less than 3V AC It is strongly recommended to use 1KVA UPS with AVR (Automatic Voltage Regulation) provision only.

Ref.: CCDWA - OM 12

5. WHEEL ALIGNMENT PARAMETERS

WHEEL ALIGNMENT refers to a set of wheel angles which are responsible to distribute the weight of the automobile over the suspension system and the four wheels uniformly when the vehicle is in motion. Proper distribution of the weight results in uniform tyre wear and effective steering control. Every vehicle manufacturer furnishes the Wheel Alignment specification for the vehicles manufactured by them.

The process of bringing and adjusting the vehicle's Geometric angles and common adjustable parameters such as Caster, Camber and Toe to its original position as per the vehicle manufacturer specification is called Wheel alignment.

WHEEL ALIGNMENT ANGLES

i) CAMBER

ii) TOE

iii) CASTER

iv) KINGPIN INCLINATION

v) THRUST ANGLE

vi) FRONT WHEEL SETBACK

vii) REAR WHEEL SETBACK

viii) WHEEL RUNOUT

ix) INCLUDED ANGLE

x) TRACK WIDTH DIFFERENCE

xi) LOCK ANGLE

xii) TOE OUT ON TURNS

Each wheel alignment angle has a specific purpose and function. If they are not set properly, the effects will be uneven tyre wear, loss of steering control, pulling to one side while driving, jerking on travel, etc.

It may not be possible to correct all the above angles in a vehicle. Depending upon the design of suspension, some angles are adjustable at workshop level and some are not adjustable (Set in Factory) which may require parts replacement to get the specified value.

The Parameters Wheel Runout, Set Back & Thrust Angle will affect the wheel angles ie., Camber & Toe. Therefore, it is very important to identify, measure and correct or compensate these angles. Otherwise, proper Wheel alignment cannot be achieved. System takes all the above factors into consideration in its design and offers total solution by compensation in the respective parameters

5.1. CAMBER The CAMBER angle will affect the wear on the inner or outer edge of the tyre. Camber is the inclination of the centerline of the wheel from the vertical as viewed from the front of the vehicle. Camber angle is measured in positive or negative degrees.

POSITIVE CAMBER is the outward tilt of the top of the tyre.

Fig. 5

Wheel angles

Steering axis angles

These are unwanted angles which sometimes prevail in a vehicle

Ref.: CCDWA - OM 13

NEGATIVE CAMBER is the inward tilt of the tyre at the top.

Fig. 6

If a tyre was absolutely vertical, the degree of camber would be zero. Unlike the Caster angle, Camber will change with vehicle load and ride height. With the weight of the driver in the vehicle, front left Camber will increase and front right Camber will decrease and vise versa for left hand steering vehicle. As rough road conditions are encountered, the downward thrust of the vehicle body will cause front Camber to go negative. As the vehicle body movement returns upward, front Camber will go positive. A tyre with Positive Camber can influence the vehicle with a directional pull. The vehicle will go towards the side that has the tyre with the most Positive Camber.

It is the normal tendency of the tyre to roll around the center of a circle when the top of the tyre is inclined towards the center of that circle. Positive Camber tends to place the tyre-to-road contact area nearer the point of load. This assists in easier steering and forces the thicker inner portion of the spindle to carry most of the load. Modern suspension design has reduced the need for considerable Positive Camber. Many manufacturers specify a slight amount of Negative Camber. Some manufacturers recommend an additional 1/4 to 1/2 degree Positive Camber on the right wheel to compensate for road crown. The car will then pull toward the side with greater Positive Camber. This will offset the pull effect of the road crown. Always set Camber within specifications.

Rear Camber Angle - Front Wheel Drive

Rear wheel Camber angle is being relied on for improved steering and general handling performance. In the past FWD vehicles and independent rear suspension vehicles were most likely to have adjustable rear Camber. On vehicles currently being produced, rear Camber adjustment capabilities are being found on all types of models (Note : Always use full-floating tables under wheels whenever alignment is being done. When alignment problems are reported on vehicles with fixed rear axles and no rear wheel Camber adjustment capabilities, a thorough inspection of the rear suspension should be made. Damaged or worn components can cause alignment and / or steering problems. Replacing or repairing the defective components should bring the rear wheel assemblies into specification.

On vehicles where rear wheel Camber is adjustable, all previous precautions apply. If Camber adjustment requirements are excessive, a thorough inspection must be performed. Replacing any defective components could bring the Camber into specification and adjustment may become unnecessary. As with the front suspension, DO NOT perform alignment on vehicles with damaged or worn components.

Rear Camber Angle - Rear Wheel Drive

On RWD vehicles, where rear Camber is usually not adjustable, Camber will normally be fixed at zero. Even though this angle cannot be changed through adjustment, if rear suspension abnormalities exist, a thorough inspection must be made. Not to be overlooked are the rear springs. Worn or weak rear springs will alter riding height and because of a reduction in tension, will bring the shock absorbers out of the optimum range of their dampening ability. The result will be excessive tire movement. This condition reduces operator control and contributes to abnormal tire wear. As in FWD vehicles, replacing worn or defective components may bring rear wheels within specification.

Ref.: CCDWA - OM 14

5.2. TOE Unlike Caster and Camber, which are measured in degrees, Toe is most frequently measured in fractional Inches, Millimeters or Decimal degrees. An incorrect Toe setting is one of the main alignment factors that cause excessive tyre wear. Front and rear Toe are the same in definition, with the adjustment capabilities and procedures being the only actual difference. TOE is the difference between the leading edge (or front) and trailing edge (or rear) of the tyres.

TOE-IN is the measurement in fractions of an Inch, Millimeters or Decimal of degrees that the tyres are closer together in the front than they are in the back.

Fig. 7

TOE-OUT is the same measurement, except the tyres are further apart in the front than in the rear.

Fig. 8

Slight Toe-in is preferred to Toe-out on most vehicles because steering is aligned while vehicle is stationary. When the vehicle is moving, linkage components flex causing a change in alignment angles. This is classified as “Running Toe”. Running Toe should be zero to maximize tyre life and achieve least rolling resistance.

The usual tendency is for the tyres to turn outward while the vehicle is in motion, so most vehicles are designed with a static Toe-in setting. The static Toe-in setting will become zero as the linkage flexes when the vehicle is in motion. Always set Toe to the manufacturer‟s specifications. On vehicles with Toe adjustment capability on the rear, an alignment specialist can go beyond manufacturer‟s specifications according to vehicle usage and customer requirements. With the proper equipment, the rear axle can be adjusted to perform aggressively toward demanding load and road conditions.

Vehicles with FWD and independent rear suspensions are more likely to have adjustable rear Toe. As with rear Camber, properly adjusted rear Toe will contribute to improved steering & handling characteristics. Full floating tables (Rotary plates) must be used under rear tyres whenever Toe is to be adjusted. If rear Toe is out of spec a thorough inspection must be done, whether or not rear Toe is adjustable.

Components found to be defective must be replaced. On vehicles that do not have rear Toe adjustment capability and Toe is not within specifications, replacing defective components may bring Toe within specifications.

Normally TOE is specified in ‘mm’ or ‘inch’. That is by how much the front of the Wheel Rim is IN or OUT compared to the rear side of the Wheel Rim. But, System follows the unit of Degrees and Minutes. Even, if the TOE is entered in ‘mm’ or ‘inch’, it converts the same into corresponding Degrees and Minutes

Ref.: CCDWA - OM 15

5.3. CASTER CASTER is the angle between an imaginary line drawn through the upper and lower steering pivots and a line perpendicular to the road surface (viewed from side of vehicle). If the top of the line tilts rearward, the vehicle is said to have POSITIVE CASTER.

Fig. 9

If the top of the line tilts forward, the vehicle is said to have NEGATIVE CASTER.

Fig. 10

Positive Caster can also be defined as when the spindle is tipped so that the pivot support centerline intersects the road surface at a point in front of the initial tire contact. Negative Caster would then be the center line intersection to the road surface behind the initial tire contact.

Most vehicles produced today do not have adjustable Caster angle. Many early model vehicles have adjustable Caster in which road crown is compensated for (along with Camber). By setting the Caster angle on the Driver‟s side 1/2 degree less than the passenger side for Positive Caster specifications or 1/2 degree more for Negative Caster specifications, the road crown should not cause vehicle pull in either direction. Vehicles equipped with manual Steering use very little Positive or Negative Caster. This helps reduce the Steering effort at the Steering wheel.

The advantage of Caster adjusted toward Negative is greater maneuverability. however, direction stability on open road driving is reduced. The advantage of Positive Caster is the strong directional stability and the ease of returning the steering to a straight ahead position. Caster will not cause tyre wear unless extreme mis-adjustment or worn parts are involved. Always set Caster (if adjustable) to specifications and within 1/2 degree from side to side. Keep road crown in mind and adjust as necessary if a pull is present after a proper alignment has been completed.

Ref.: CCDWA - OM 16

5.4. KINGPIN INCLINATION (Steering axis inclination)

Fig. 11

KINGPIN Inclination (also referred to as the ball joint angle or Steering Axis Inclination-SAI) can be a difficult angle to understand. The easiest way to understand Kingpin Inclination is to first define Steering axis. The steering axis is an imaginary line intersecting the spindle support. In a conventional steering system, the spindle supports are the upper and lower ball joints or the Kingpins. With MacPherson strut systems, Steering axis is the angle beginning at the ball joint and extended through the strut assembly. Viewed from the front of the vehicle, Kingpin Inclination is the angle between the Steering axis and a true vertical line established through the tyre. The Kingpin Inclination is a stability angle and is measured in degrees.

If these imaginary lines were extended to road surface, the area covered between them would be identified as the point of load or scrub radius. The vehicle body will be closest to the road surface when the wheels are pointed Straight Ahead as a result of Kingpin Inclination.

A spindle with Kingpin Inclination will have the outer end of that spindle at the highest point when the wheels are pointed Straight Ahead. Therefore, as the weight of the vehicle pushes downward, the spindle will always attempt to move upward to return the wheels to a Straight Ahead position. After a turn, the Kingpin Inclination helps to return the tyres to Straight Ahead position. Kingpin Inclination also aids in vehicle directional stability by resisting road irregularities that attempt to turn the wheels away from the Straight-ahead position. This angle produces many of the same benefits that improve steering stability as Positive Caster. Correct engineering of Kingpin Inclination can reduce the need for high Positive Camber. The effect of Kingpin Inclination on directional stability is usually greater then that of Caster. Some vehicles with Power steering require a greater amount of steering wheel returning force than those with manual steering. Kingpin Inclination is often used with Positive Caster on power steering equipped vehicles to assist in steering wheel returnability.

Ref.: CCDWA - OM 17

5.5. THRUST ANGLE

Fig. 12

THRUST ANGLE is the line that divides the total angle of the rear wheels. The rear tyres are not just following the front tyres, they are actually establishing direction of the vehicle. In doing so, a direction of thrust is developed. The Thrust angle created by the rear wheels is used as a reference for aligning the front wheels. Ideally, the Thrust angle should be identical to the geometric centerline of the vehicle. If Thrust angle and geometric centerline are identical, the position of the tires would then form an absolute rectangle and the front tyres could be aligned to the rear tyres, resulting in a perfectly centered steering wheel. Because of unitized construction, factory tolerances and a varying degree of damage and / or wear, it is increasingly unlikely that the axles will be parallel. When the rear axle projects a different angle than the front axle, the driver will need to turn the steering wheel to compensate in order to drive in a straight line.

On situations where the thrust line and geometric centerline are not identical, a thorough inspection of the rear axle and suspension system must be done. Replacing defective components should aid in positioning Thrust angle close to the geometric centerline. If the Thrust angle is not identical to the geometric centerline and there are no defective components, align the vehicle using the Thrust angle instead of the geometric centerline. Aligning the front wheels to the Thrust angle is preferred to aligning to the geometric centerline. The ability to do this is a significant advantage of four wheel alignment. The result should be a straight steering wheel as the vehicle moves straight-ahead.

Ref.: CCDWA - OM 18

5.6. FRONT WHEEL SETBACK FRONT WHEEL SETBACK or front end squareness is a condition in which one wheel is rearward of the other. If Setback is present the turning radius will not be correct when the vehicle turns. With this condition, the tyres will wear very much in the same manner as if they were under inflated. Generally, Setback is the result of collision damage. It is preferable to have the front tyres square with each other before alignment is done. The most accurate way of checking is with four wheel alignment equipment.

The measured angle will be displayed as Negative Front wheel Setback, if the Right Rear wheel leads the Left Rear wheel.

Fig. 13

The measured angle will be displayed as Positive Front wheel Setback, if the Right Rear wheel is behind with respect to the Left Rear wheel.

Fig. 14

Ref.: CCDWA - OM 19

5.7. REAR WHEEL SETBACK It is the condition of Rear axle with respect to the Geometric centre line ie., one of the Rear wheel is rearward or forward with respect to the other wheel. The Rear Wheel Setback is the angle between a line drawn through both the wheel resting points. A line perpendicular to the vehicle geometrical line (thrust line) will be measured in angles.

The measured angle will be displayed as Negative Rear wheel Setback, if the Right Rear wheel leads the Left Rear wheel.

Fig. 15

The measured angle will be displayed as Positive Rear wheel Setback, if the Right Rear wheel is behind with respect to the Left Rear wheel.

Fig. 16

Ref.: CCDWA - OM 20

5.8. WHEEL RUNOUT

Fig. 17

RUNOUT is one of the important factor which affects a good wheel alignment. Hence Runout compensation is a critical parameter in wheel alignment.

Runout is the wobbling of wheel with respect to neutral axis ie., vertical axis of Camber and the axis parallel to Geometric centre line in case of Toe. This wobbling affects the Camber and Toe parameters. Runout exists even in new vehicles. But it will be more in old vehicles due to wear and tear. Now let us see how Runout affects the Camber:

TR

UE

VE

RT

ICA

L

10

' (M

INIM

UM

)

30

' (A

VE

RA

GE

)

50

' (M

AX

IMU

M)

ROAD Fig. 18

Assume that there is a wobbling of 10' to 50' in a wheel and Runout is 40' (max. – min. reading). This means, when the vehicle is in motion, the wheel will have a varying Camber of 10' to 50' during every rotation. This is inevitable. Logically the average point has to be taken as the real Camber (ie., 30' in this case).

If the specified Camber for a vehicle is 55', then adjustments must be made in the shims / Cam mechanism suitably to affect a wobbling movement of 25' to achieve the average Camber of 55' (ie., 30' + 25' = 55').

After the adjustment, Average Camber = 55' (required)

Minimum Camber = 35‟

Maximum Camber = 75‟

TR

UE

VE

RT

ICA

L

35

' (M

INIM

UM

)

55

' (A

VE

RA

GE

)

75

' (M

AX

IMU

M)

ROAD Fig. 19

Ref.: CCDWA - OM 21

Due to the above adjustments, Camber variations will be equally distributed in the vehicle (in motion) at any point of time. The process of bringing the Camber to average Runout position is called Runout compensation.

The equipment does the Runout compensation automatically without the knowledge of technician.

In Jacked up Runout method, the Technician has to simply rotate the wheel as guided by equipment for 90°and drop the wheel on Rotary plate.

In Roll-on Runout method, the wheel has to be rotated only at 90° backward from the parked position.

Rest of the calculations is automatic and average Runout compensation is achieved.

Above theory is also applicable for achieving the average Runout compensation in Toe setting.

Once Camber & Toe Runout are compensated, best results can be expected in terms of wheel alignment.

5.9. INCLUDED ANGLE

Fig. 20

INCLUDED ANGLE is the angle formed between the Kingpin inclination and the Camber. Included angle is not directly measurable. To determine the Included angle, Kingpin Inclination is added to the Camber. If the Camber is negative, then the Included angle will be less than the Kingpin Inclination. If the Camber is positive, it will be greater. The Included angle must be the same from side to side even if the Camber is different. If it is not the same, then something is bent, most likely the steering knuckles.

Ref.: CCDWA - OM 22

5.10. TRACK WIDTH DIFFERENCE Track width difference is the angle between Front Left wheel resting point to Rear Left wheel resting point & Front Right wheel resting point to Rear Right wheel resting point.

Fig. 21

The measured angle will be displayed as Positive angle, if the Rear Track width is more than the Front Track width.

The measured angle will be displayed as Negative angle, if the Front Track width is more than the Rear Track width.

Ref.: CCDWA - OM 23

5.11. LOCK ANGLE

Fig. 22

LOCK ANGLE is the angle measured in degrees by which the front wheels of a vehicle move to the extreme left or right from the straight ahead position when steered.

Left wheel Lock Angle : The maximum degrees to which the left front wheel can (Internal) turn when the wheels are steered to the left side.

Left wheel Lock Angle : The angle turned by left wheel when the right wheel is (External) steered to max. right is called Lock Angle External (Left).

Right wheel Lock Angle : The maximum degrees to which the right front wheels can (Internal) turn when the wheels are steered to the right side.

Right wheel Lock Angle : The angle turned by right wheel when the left wheel is (External) steered to max. left is called Lock Angle External (Right).

Lock angles for the right and left side are controlled by stoppers provided on both sides. Lock angle also determines the minimum turning radius of a vehicle.

The Lock angle varies from 35º to 42º depending upon the make of the vehicle. The Lock angles may get disturbed due to the following factors:

i. When Steering linkages are bent due to the vehicle meeting with any accident.

ii. Improper adjustments of stoppers.

Iii. Incorrect setting of steering rack, pitman arm and tie rod lengths.

Lock angles are measured to ensure that the front wheels turn equally on both sides (right & left) as per manufacturer‟s specification.

Ref.: CCDWA - OM 24

5.12. TOE OUT ON TURNS When the front wheels of a vehicle are steered to left or right, the angle turned by each wheel at any instant is not equal. When the left wheel is turned towards left side by 20° from the Straight ahead position the right side wheel would have turned lesser than 20°. If the Toe is measured at this instant, it will always be in „Toe-out‟ condition.

Fig. 23

The difference between the angle turned by left and right wheel is responsible for the Toe-out condition.

Let a = the angle turned by left wheel. i.e., the angle made by the rear axle centre line produced and a line drawn perpendicular to the plane of the left wheel from its centre.

Let b = the angle turned by right wheel. i.e., the angle made by the rear axle centre line produced and a line drawn perpendicular to the plane of the right wheel from its centre.

(a - b) = rL is the difference in angle turned by left and right wheels.

Similarly when the right front wheel is turned 20° towards right side, the left side wheel would have turned less than 20° because of the Ackerman principle employed in the steering system.

The difference in angle turned by the front wheels during left turns (rL) and right turns (rR) should be equal or within allowable tolerance.

If rL & rR are not equal or not within limits, then it indicates

i. Bent Steering link

ii. Wrong positioning of pitman arm in the Steering box

iii. Not centralizing the rack in the steering box in the straight ahead position

Ref.: CCDWA - OM 25

6. DESCRIPTION OF MAIN PARTS

The equipment consists of Main Cabinet, Display unit, RF Transceiver unit, Sensor arms, Arm resting brackets, Keyboard, Mouse and Standard accessories. The Optional accessories indicated will be supplied only against order.

4

11

9

6d

6b

7

5

6c

8

6a

10

3

1

2

Fig. 24

Sl.No. Description Sl.No. Description

1 Main cabinet 7 Arm resting brackets

2 Desktop computer (refer scope of supply) 8 Keyboard (refer scope of supply)

3 Interface box 9 Mouse (refer scope of supply)

4 Display unit (refer scope of supply) 10 Color Inkjet printer (refer scope of supply)

5 RF Transceiver unit 11 Multimedia speakers (refer scope of supply)

6.a Sensor arm-Front-Left

6.b Sensor arm-Front-Right

6.c Sensor arm-Rear-Left

6.d Sensor arm-Rear-Right

Ref.: CCDWA - OM 26

6.1. MAIN CABINET Main cabinet is the housing for Desktop computer, PC Interface unit with Power panel & Printer (Optional). The Display unit is mounted on a Monitor column over the top of Main cabinet. The RF Transceiver unit, Keyboard, Mouse & Multimedia speakers (Optional) are located on the respective slots in Main cabinet top cover.

The Arm resting brackets are provided on the sides of Main cabinet for placing the Sensor arms when not in use.

6.2. DESKTOP COMPUTER (refer scope of supply) The Desktop computer is a Commercial branded computer integrated with our Aligner and housed inside the Main cabinet for processing / executing the alignment program and data storage. The location of Desktop devices and peripherals connection ports may vary depending upon the manufacturer. However the following user end devices and connection ports available commonly in all models are used for our application:

Device / connection ports Location Purpose

Optical drive Front side For loading / upgrading software

3 Pin AC socket (Male) Rear side AC input to Desktop

VGA out Rear side For Monitor

PS/2 ports Rear side For Keyboard & Mouse

Serial port (COM1) Rear side For communication with PC interface unit

USB ports Front / Rear side For communication with PC Interface unit, Keyboard, Mouse, Printer, Speakers

Audio output Front / Rear side For Multimedia Speaker

Keep the Desktop away from radiators and heat sources

Desktop contains Optical drives which have built-in laser devices. To prevent any risk of exposure to laser radiation, do not open the desktop / drives

Ensure that none of the system air vents are blocked. Blocking them would cause serious thermal problems

Clean the Desktop with a soft & clean cloth using water and then remove moisture from the surface quickly. Long term exposure to moisture may damage the surface

The location / functions of Desktop devices / connections may vary depending upon the make of Desktop supplied. Refer Desktop manual / Soft media

6.3. INTERFACE BOX Interface box is used for distributing & regulating the power supply required for the Aligner and also to interface the Desktop computer (Processing unit) with alignment system assemblies like Sensor arm & RF Transceiver unit.

Connectors, Ports and sockets are provided in at the rear side of Interface box for connecting the RF Transceiver unit, Sensor arm cables, Arm resting brackets, Desktop computer and peripherals like Monitor, Printer, Speakers. The locations are shown in the Fig.25 & 26 below.

The ON/OFF switch provided in the Interface box can be used to switch OFF the Processing unit alone

Control fuses are provided in the Interface box as described below:

Control fuse - F1 is provided for protection of all electronic components in PC I/F unit

Specifications – 3A, Dia 5mm x 20mm, Slow blow type Glass fuse

Control fuse - F2 is provided for protection of Monitor, Printer & Speaker

Specifications – 5A, Dia 6.35mm x 31.8mm, Slow blow type Glass fuse

Ref.: CCDWA - OM 27

Interface box - Front view

3

2

ON

OFF

SW1

5 Amps

F2

230V AC50 HzINPUT

F1 3 AmpsMONITOR POWER

PC

9

USB

46 8 75

1

Fig. 25

Interface box - Rear view (inside the Main cabinet)

10

1112

230V AC ± 10%,50 Hz

CAUTION

SERIAL PORT

11 Fig. 26

Sl.No. Description Sl.No. Description

1 RF Transceiver unit connector 7 AC input for PC Interface unit

2 Sensor arm connectors 8 Fuse F1 for PC Interface unit

3 ON/OFF switch (Processing unit) 9 USB port for Desktop computer

4 Fuse F2 for Monitor & Peripherals 10 AC output for Printer & Speaker

5 AC output for Monitor 11 Charger connectors

6 AC output for Desktop computer 12 Serial port for Desktop computer

6.4. DISPLAY UNIT (refer scope of supply) The Display unit is a High resolution Color Monitor to display the alignment screens and functions. It contains a Power indicator LED, Power ON/OFF switch and various adjustments. Refer the Monitor manual / Soft media provided along with the equipment for adjustments.

Ensure that none of the Monitor air vents are blocked. Blocking them would cause serious thermal problems

Clean the Monitor with a soft & clean cloth using water. Remove moisture from the display quickly and keep the display dry. Long term exposure to moisture may damage the display

The location of Monitor power indicator and controls may change depending upon the make of the Monitor supplied. Refer the Monitor manual / Soft media

Ref.: CCDWA - OM 28

6.5. RF TRANSCEIVER UNIT The RF Transceiver unit has a built-in Hardware lock for protecting the alignment program against un-authorised usage and also for enabling the Optional features in the field itself by providing the activation code acquired from Manufacturer with respect to the Machine Serial Number.

A Transceiver module is housed inside RF Transceiver unit to interface with processing unit & Sensor arms by transmitting & receiving commands / alignment data for process.

Wheel aligner has an exclusive provision for programming its RF channel (upto 15 channels) in the field itself to avoid any external co-channel interference from other equipments.

Indicators are provided in the RF Transceiver unit for power status and direction of data flow as given below:

Fig. 27

Indicator LED color

Status

Power Red Availability of power supply

TX Red Data transmission from RF Transceiver unit

FL Green Data received from Front Left Sensor arm

FR Green Data received from Front Right Sensor arm

RL Green Data received from Rear Left Sensor arm

RR Green Data received from Rear Right Sensor arm

The equipment radiates Radio Frequency @ 2.4 GHz. Usage of this equipment in residential / commercial area may cause interference to some appliances. In such case the user can contact our Service personnel for re-programming the Aligner's RF channel or else the user should take whatever remedy required to correct the interference on his own expense. The manufacturer is not responsible for any claim

RF channel setting should be done only by authorised Service personnel

DO NOT disturb the location / orientation of the RF Transceiver unit. It will directly affect the data transmission to Main processing unit, leading to improper data communication

6.6. SENSOR ARMS Front and Rear Sensor arms contain High precision Inclinometers and CMOS Camera to measure and acquire required alignment parameters from the Vehicle being aligned.

A Spirit level is provided in each Sensor arms for ensuring its horizontality.

Handle the Sensor arms carefully. Rough handling / shocks may cause damage to the Sensors and optical components

Dropping / rough handling of Sensor arms may cause deviation in calibration. User should take atmost care to handle and maintain the Sensor arms in good calibrated condition

The data acquired by each Sensor arms are transmitted to the RF Transceiver unit through Transceiver module in each Sensor arms using Radio Frequency of 2.4 GHz.

Auto charging batteries are provided inside the Sensor arm tubes for storage of DC power required for carrying out alignment.

Ref.: CCDWA - OM 29

Battery specifications : 7.2 AH, 6V x 1 Valve regulated Lead Acid

Backup time : >12 hours

Provision (5 Pin BSM type connector) is available in the Sensor arm cabinet for operating each Sensor arms independently using Sensor arm cable also, which is provided as Optional accessory.

While operating a particular Sensor arm using the Optional cable, the Sensor arm will get charged simultaneously.

Control fuse is provided in all Sensor arms for protection of all electronic components

Specifications – 1A, dia 5 mm x 20 mm, Slow blow type glass fuse

Never heat the Battery or throw into fire. Keep the Battery / charging contacts away from metal objects

DO NOT try to clean or disassemble the Battery as it could result in the leakage of sulfuric acid resulting in acid burns

Scrap batteries should be stored in non-reactive acid resistant containers. It is the responsibility of End-User to comply with the Battery (M&H) rules of National regulatory authority and hand over scrap batteries to the Authorised collection centres

Sensor arm batteries should be replaced with same model only by qualified Service personnel, if required. Refer the Battery label for Make / Model details

Sensor arms should not be kept idle if alignment is not caried out. Failure to comply may lead Battery lead deep discharge and Battery failure

If Sensor arms are kept idle & not placed in Arm resting brackets, a continuous beep sound will be generated after 10 minutes with 2 minutes interval

When alignment is not carried out, the Sensor arms must be placed on the Arm resting brackets for auto-charging the batteries fixed inside Sensor arm tube

Ensure that the Charging LED glows in Red color when Sensor arm is kept on the Resting bracket or connected with Optional Sensor arm cable for charging

If Low battery is indicated, Sensor arm may not communicate data with RF unit properly. Keep the Sensor arms on the Resting brackets for charging

DO NOT switch OFF the Main system switch, let the battery get charged over night

SENSOR ARM INDICATORS & KEYPAD CONTROLS

Fig. 28

Indicator LED color

Status

Power ON Green During usage, as soon as the Sensor arm is lifted from Arm Resting bracket

Charging Red

During charging of Sensor arm,

By placing it on the Arm Resting bracket (or)

Using Sensor arm cable (Optional)

Low battery Red When battery level goes below its normal operating voltage

Keys Functions Runout Red

Indicator to press Runout key for performing Runout Enter To proceed to next program

Prev To skip current operation and go to previous step

Audio indication

-

Indicator (after 10 min.) to switch off Sensor arm during Mains power supply cutoff (or) if comm error occurs between RF Transceiver unit & Sensor arms

Next To go to next window

Runout To be pressed in each step of RUNOUT

The use of cleaning agents which attack coating or sealing materials could result in Membrane damage

Ref.: CCDWA - OM 30

During RUNOUT program, "PREV" key also is used to redo the RUNOUT

Front / Rear Sensor arms (Rpac Premium Plus models)

Rear Sensor arms (Rpac Premium models)

Fig. 29

Fig. 30

6.7. ARM RESTING BRACKETS Arm restring brackets are provided on the sides of the Main cabinet for resting the four Sensor arms when it is not in use.

Resting brackets have charging facility for charging the Sensor arms. Sensor arms should be charged for minimum 6 to 8 hours for un-interrupted alignment operation.

Never heat the Battery or throw into fire. Keep the Battery / charging contacts away from metal objects

DO NOT short the Charging pins in Resting bracket which may lead to malfunction of charger

6.8. KEYBOARD (refer scope of supply) A standard USB or PS/2 Keyboard is connected to Desktop computer and placed over the Cabinet top cover. The Keyboard is provided for operating / navigating and giving inputs during the alignment program.

The location of Indicators and functions of Keys may change depending upon the make of the Keyboard supplied. Refer Keyboard manual / Soft media

The functions of active keys in the Wheel aligner program are given below. Functions of a same key may differ depending on the program screen & context.

6.9. MOUSE (refer scope of supply) A standard Optical Mouse is connected to Desktop computer and placed over the Cabinet top cover. The Mouse is provided for operating / navigating and giving inputs during the alignment program.

The location / functions of Keys may change depending upon the make of the Mouse supplied. Refer Mouse manual / Soft media

Sensor arm knob

Ref.: CCDWA - OM 31

6.10. STANDARD ACCESSORIES

Use only the Accessories recommended by the manufacturer and handle it carefully. Failure to comply may cause injury to Operator

Frequently inspect the accessories and clean and lubricate

6.10.1. WHEEL BRACKET

Fig. 31

This is a Self centering type Wheel bracket with quick clamping feature for mounting the Sensor arm to Wheel rims The Wheel bracket is a versatile design to accommodate LCV Wheel rims ranging from 12" to 24" of diameter. The Inner PCD holes will cover from 12” to 20” sizes of rim & Outer PCD holes will cover from20” to 24” sizes of rim.

Handle the Wheel bracket with care. The Locating pins may have sharp edges

Wheel bracket must be mounted on the wheel at 12 O clock positions (true vertical position) if the center block is slide down for spoiler program. If not, it will measure wrong Wheel setback

Clamping of Alloy wheels 1. Outer clamping is advised for Alloy wheel. Extend the clamp outward to

a size larger than the rim by turning the Wheel bracket knob in Anti-clockwise direction.

2. Place the upper Locking pins on the outside of the top of the rim. Push the Locking pin in between the Tyre bead and the rim. It may be necessary to "pop" the upper portion of the Wheel bracket with the palm of your hand to seat well. Note that it is not necessary for the Wheel bracket to be mounted perfectly vertical on the wheel.

3. Push lower Locking pins into place. Again, it may be necessary to pop them in further for security. Continue tightening knob until it is secured.

4. Tighten the Wheel bracket by turning the knob in clockwise direction until the lower Locking pins engage the rim.

5. Ensure the mounting by pulling the Wheel bracket outwards. If it comes off easily, re-mount the Wheel bracket properly.

Clamping of ordinary steel rim wheels To clamp the wheel from the inside out using the outer lip of the rim, use the following steps:

1. Extend the Wheel bracket inwards to a size smaller than the rim by turning the Wheel bracket knob in clockwise direction.

2. Place the lower locking pins on the wheel lip at the bottom of the wheel. It is not necessary to be perfectly vertical.

3. Tighten the Bracket by turning the knob in anti-clockwise direction until the upper Locking pins engage the rim. Continue to tighten until the Wheel bracket is secure.

4. Test the security by pulling the Wheel bracket outwards. If it comes off easily, re-mount the Wheel bracket.

Sensor arm locking knob

Wheel bracket knob

Ref.: CCDWA - OM 32

6.10.2. LCV ROTARY PLATE - 2 ton (Applicable only for LCV models)

Fig. 32

The Rotary plate consists of a freely rotating plate with load capacity of 2 ton in each Rotary plate suitable for LCVs. The front wheels of the vehicle being aligned should rest on these plates. The Rotary plate helps to free up the wheel from the friction and relaxing the ball joint to its original condition. Lock pins are provided to arrest the movement of rotation while parking the vehicle over the plate for alignment. The Locking pins must be removed while taking measurements.

(a) The Rotary plates enable Left turn and Right turn movement required for measuring Caster & Kingpin angles.

During Rear wheel alignment, the Rear wheels are to be rested on the Rear wheel slider to accommodate the minor wheel movements.

Ensure the Top plate of Rotary plates are locked with Locking pins before parking the vehicle

The Rotary plate must be maintained properly by user free from dust

6.10.3. LCV BRAKE PEDAL LOCK

Fig. 33

Brake pedal lock is used to keep the Vehicle Brake in pressed condition (applied), so that the vehicle will not move during the Turn Left and Turn Right programs, which is very important to measure the Caster and Kingpin.

Ensure the Brake pedal lock is pressed against the vehicle brake

Ensure the Brake pedal lock is pressed against the vehicle brake during Caster & Kingpin swing to acquire readings

6.10.4. STEERING LOCK

Fig. 34

Steering lock is used to arrest the movement of Steering wheel, while performing the Toe adjustment.

Do not keep your head nearer to the Steering while locking with Steering lock to avoid get hit due to the spring tension

Ref.: CCDWA - OM 33

6.10.5. DATA MANAGER SOFTWARE Data manager is a smart customised software package available with alignment program for monitoring the condition of various vehicles aligned by the equipment and the performance of Wheel alignment centre on the whole. Reminder letters are automatically generated for existing customer base periodically, which helps in increasing the revenue for the garage.

6.11. OPTIONAL ACCESSORIES

6.11.1. MECHANICAL ROTARY PLATE WITH ANGLE INDICATOR (For Toe Out on Turns and Lock Angle measurement)

Fig. 35

Rotary plate consists of a freely rotating plate, an Angular scale and a Pointer fixed to its centre axis of rotation. While carrying out alignment, the front wheels of the vehicle being aligned will rest on these plates.

The functions of the Rotary plates are the following:

(a) Enables easy rotation of front wheels during Left turn and Right turn movement required for measuring Caster and Kingpin angles.

(b) Measures the Toe out On Turns and Lock Angle for Front wheels.

The known angle is noted manually and given as input to the Main processing unit for measurement

LCV Electronic Rotary Plate load capacity = 2 ton (each)

During Rear wheel alignment, the rear wheels are to be rested on the Rear wheel slider to accommodate the minor wheel movements.


The Rotary plate must be maintained properly by user free from dust

6.11.2. WHEEL BRACKET EXTENSION ADAPTER This Adapter is very useful for clamping wheel rims of 10” to 26” dia., while using along with Wheel bracket (whose clamping range is 12”-24” dia). This adapter eliminates requirement of a separate Wheel bracket for HCV wheels.

Fig. 36

Ref.: CCDWA - OM 34

6.11.3. FOUR SHAFT CALIBRATION KIT

Fig. 37

Calibration kit is a simplified tool meant for calibrating the all the Sensor arms simultaneously and if necessary to correct it.

Calibration is a very important function. During this process, the Calibration stand should not be jerked or moved

6.11.4. SINGLE SHAFT CALIBRATION KIT

Fig. 38

Calibration kit is a simplified tool meant for calibrating the System and if necessary to correct it.

This Calibration kit is supplied in a dismantled condition along with 0° and 6° Spirit levels in a compact and portable casing.

Calibration is a very important function. During this process, the Calibration kit should be leveled using the bubble level

Calibration is a very important function. During this process, the Calibration kit should not be jerked or moved

6.11.5. RIM LOCKING PIN (HCV) Wheel rim locking pin with 100mm Length is exclusively for clamping HCV alloy wheels by fitting with the Wheel bracket unit.

Fig. 39

6.11.6. RIM LOCKING PIN (suitable for Run flat tyre rims) This Rim locking pin of 64mm Lg. is developed for clamping different kind of LCV Run flat tyre rim profiles, compatible with 24" Wheel bracket.

Fig. 40

6.11.7. RIM LOCKING PIN (suitable for Steel rims with fancy disc) This Rim locking pins of 64mm Lg. is developed for clamping different kind of LCV Steel rims with fancy disc, compatible with 24" Wheel bracket.

Fig. 41

Ref.: CCDWA - OM 35

6.11.8. REAR WHEEL SLIDER

Fig. 42

Rear wheel slider is used for Four wheel alignment. Rear wheels will rest on these Sliders to enable lateral movement of wheels during Rear wheel alignment.

The Rear wheel slider must be maintained properly by user free from dust

6.11.9. LONGER REAR WHEEL SLIDER

Fig. 43

This Rear wheel slider is used to accommodate wide range of wheel base (1800 to 2600mm) during Four wheel alignment. The Rear wheels will rest on the Sliding top plate with Rollers underneath to facilitate carrying out the push pull Runout & sliding movements in all the directions for easy adjustment of Rear wheel Camber / Toe. Lock pins are provided to arrest the movement while parking the vehicle over the Slider for alignment. The Locking pins must be removed while taking measurements

The Rear wheel slider must be maintained properly by user free from dust

6.11.10. SENSOR ARM CABLE KIT The Sensor arm cables are a set of Shielded Multi-core cables used for connecting the Sensor arms and Power panel with 5 Pin BSM type connectors to perform the following functions:

To transmit data acquired by each Sensor Arms to Main processing unit.

To charge the Sensor arm batteries simultaneously during operation.

Ensure the cables are not in contact with Rotary plate / moving parts / vehicle tyre

Store the Sensor arm cables properly without any twist when not in use

DO NOT use damaged / twisted Sensor arm cables. It will directly affect the data transmission to Main processing unit

the data transmission to Main processing unit

6.11.11. PRINTER (refer scope of supply) A Printer option is provided with the equipment for printing the alignment reports in ISO A4 size paper. The User is provided with options for printing the alignment reports in Ordinary or in 3D Graphical format as per the requirement.

Use only original Ink/Toner cartridge, by indicating the respective Cartridge Model No., Printer Make & Model No. to supplier. Failing to comply may lead to Printer head damage / improper printout

Ref.: CCDWA - OM 36

Use only standard ISO A4 size papers (210 x 297 mm) recommended by the Printer manufacturer and always ensure sufficient quantities of paper is loaded in the Printer tray. Failing to comply may lead to Improper printing / Paper jam / Printer head damage

Clean the Printer with a soft & clean cloth using water and then remove moisture from the surface quickly. Long term exposure to moisture may damage the surface

Location of Indicators and Control buttons may change depending upon the make of Printer supplied. Refer Printer manual / Soft media

6.11.12. MULTIMEDIA SPEAKER (refer scope of supply) Multimedia speakers (2 Nos.) are used for providing voice prompts to guide the operator throughout the alignment program.

Location of Indicators and Control buttons may change depending upon the make of Speaker supplied. Refer Printer manual / Soft media

6.11.13. INTERNATIONAL VEHICLE DATA (refer scope of supply) This is an Optional feature to be activated via Built-in Hardware lock by purchasing at extra cost. The readily available vehicle specifications that are compiled and released by Third parties with License can be directly uploaded in our system. These vehicle specifications are updated & released twice every year at extra cost

Ref.: CCDWA - OM 37

7. OPERATION

Only permit qualified personnel to operate, maintain or repair the Aligner

Handle the Sensor arms carefully. Rough handling / shocks may cause damage to the Sensor and optical components

Do not move or turn the equipment while the System is in power up condition


Always comply with the applicable accident prevention regulations

Do not hammer or hit any part of the equipment with service Tools

Do not operate the equipment under direct sunlight. Even reflected sunlight reaching the Sensor arm camera will result in erratic readings

During mains power cutoff (or) if communication error occurs between Transceiver unit & Sensor arms in idle condition, an audio indication will be given to switch off the Sensor arms or to rest it on the Charging tray

7.1. DEFECTS / MALFUNCTIONS

In case of defects or malfunctions, turn OFF the mains and contact qualified Service personnel

7.2. PRELIMINARY ALIGNMENT PREPARATION 1. It is vital to collect the required information / complaint on vehicle being aligned

from the vehicle owner prior to diagnosis for conducting a perfect alignment.

2. Perform a test drive to verify owner‟s complaint.

3. Ensure that Top plates of Rotary plates are locked with Locking pins.

4. Position the vehicle on Alignment pit / Alignment lift

a) For conducting alignment on Alignment pit, refer Chapter 7.2.1.

b) For conducting alignment on Alignment lift, refer Chapter 7.2.2.

5. Inspect the vehicle tyres for correct size & for any signs of abnormal wear & tear.

6. Always check for correct tyre pressure in all the four wheels. The tyre pressure must be uniform for both front wheels and for both rear wheels as per the specification.

Unequal Tyre pressure may lead to improper alignment

7. Inspect the vehicle parts like Front & Rear suspensions, Bearings, Steering, Ball joints, Tie rod etc., thoroughly for any play / looseness / wear & tear. Replace the defective parts if any.

8. Ensure that there is no excessive free play in steering mechanism and linkage.

9. Adjust the Wheel bearings if required.

10. Ensure that there is no excessive Runout in the wheels.

11. Place the Test loads in vehicle (if specified in Vehicle manual).

12. Mount the four Sensor arms on wheels using appropriate Wheel brackets. Wind the Safety rope around Wheel bracket and hook both the ends to the Wheel rim.

13. Re-center the Steering wheel & re-adjust Front Toe if needed – crooked Steering wheels are the leading cause of customer dissatisfaction with wheel alignments.

14. Take a printout for comparing the results before and after alignment

15. Balancing of the wheels is also recommended before alignment.

Ref.: CCDWA - OM 38

7.2.1. ALIGNMENT USING ALIGNMENT PIT Park the Vehicle in the Alignment bay so that both the Front wheels rest on exact centre of Rotary plates and the Rear wheels rest on Rear wheel sliders.

7.2.2. ALIGNMENT USING ALIGNMENT LIFT

Secure the vehicle with the Alignment lift properly as instructed by the Lift manufacturer. Failure to comply may lead to risk of crushing or serious injury, if vehicle rolls off the lift

Leave Automatic transmission in park or Manual transmission in gear unless equipment operation steps require vehicle in Neutral

Apply Parking brake unless equipment operation steps require wheel movement

Use Wheel stopper whenever vehicle is positioned on the Alignment lift

Follow the Alignment lift manufacturer’s safety recommendations

while lifting a vehicle. MANUFACTURER IS NOT LIABLE FOR ANY DAMAGES CAUSED due to non-compliance

1. Drive the vehicle over the Alignment lift and stop just before the Rotary plates. Ensure the vehicle is centered on the bay.

2. Place the Vehicle in Park (or in Gear on a standard transmission), and turn OFF the Ignition system. Press and lock the Vehicle brake using appropriate Brake pedal lock.

3. Place Wheel chocks behind the tyres to prevent the vehicle from rolling off the lift.

4. Position the Rotary plates as needed to insure the wheels are centered.

5. Bring the vehicle to Neutral condition and release Brake pedal lock and move the vehicle forward to place over the Rotary plates. Now reposition the Wheel chocks and change the vehicle transmission to Park and then apply Brake pedal lock.

6. Raise the Lift to a solid, level lock position.

7. Place the Transmission in Neutral and release the parking brake just before beginning the Vehicle positioning process.

Ref.: CCDWA - OM 39

7.3. MAIN MENU When the equipment is switched ON, Windows Operating System will boot up and then the system will initialize all the devices. A Welcome screen will be displayed with following options:

Fig. 44

START To conduct Wheel alignment

ALIGNMENT First, existing condition of Rear wheels will be measured & displayed. Then the Rear wheel parameters are corrected and Thrust angle is compensated in Front Toe during Front wheel alignment. It reduces Tyre wear and improves the vehicle performance.

Refer Chapter 7.4 for details

SETTINGS To go to Special options

Special Options is to perform all system related activities, such as Vehicle specification entry etc. Since this a critical function dealing with Calibration etc., a Password (Default password: supervisor) is given to the customer to access Special options. Normally this Password must be kept as a secret by a responsible person, say the Owner of the Shop. If by chance the Password has come to other‟s knowledge, a Password modification provision is also given, using which the owner can change the Password.


HELP To access On-line help

Online help can be accessed from all the screens by pressing F1 key to guide the user while performing alignment

LANGUAGE To set the Language

SETTINGS User can select the preferred language out of the available options so as to display the alignment screens and Voice prompts in their regional languages


DATA To enter into Data Manager Software

MANAGER Data manager is smart customised software for monitoring condition of various vehicles aligned by the equipment and the performance of the Wheel alignment centre on the whole.


QUICK WHEEL This program can be selected in order to avoid elaborate alignment

ALIGNMENT procedure and to save alignment time

Refer Chapter 7.5 for details.

SHUTDOWN To Shutdown the program

To avoid damaging important files, it is necessary to shut down Windows properly before turning OFF or restarting the aligner

Ref.: CCDWA - OM 40

SCREEN BUTTONS & ITS FUNCTIONS

To go to previous screen

To redo Caster

To go to next screen

To view additional parameter of Rear wheels

To skip the current operation

To view additional parameter of Front wheels

To go to Welcome screen

To view Vehicle specifications

To save the data

To view vehicle data

To print Data / Report

To add new Vehicle data

To view the Report

To edit existing vehicle data

To export as PDF document

To export vehicle data

Help

To save Vehicle data

To select the Vehicle

To delete existing vehicle data

To enter the Vehicle data

To add User name & password

To view / edit Vehicle Inspection

To edit User name & password

To redo alignment

To save User name & password

To perform Runout

To delete User name & password

To compensate the uneven Lift platform at different heights

Ref.: CCDWA - OM 41

7.4. ALIGNMENT

Keep hands & other body parts away from jacking surfaces. Follow jack manufacturer’s safety recommendations. Failure to comply may lead to injury

Press CTRL+S to save the data and come to Desktop during alignment sequence

Battery status of all the Sensor arms will be indicated on Left & Right sides of the Screen respectively

If START ALIGNMENT button is pressed in the Welcome screen, User Login screen will be displayed:

Fig. 45

Select the required User & key-in the password to enter into Vehicle selection screen:

Note: If no user ID is created, use Default user for further operation.

Fig. 46

To view Battery & RF signal status, V key or RF SIGNAL & BATTERY STATUS button can be pressed in any screen

Ref.: CCDWA - OM 42

7.4.1. VEHICLE SELECTION Select the Vehicle databank from the following options in the screen: 1. European Vehicle data 2. United States Vehicle data 3. Brazilian Vehicle data 4. Indian Vehicle data 5. User defined Vehicle data 6. Unspecified Vehicle data On selection of required Vehicle databank, following screen will be displayed:

Fig. 47

Vehicle specifications can be selected between "Initial measurement completed" and "Alignment completed" screens

7.4.1.1 NORMAL VEHICLE SELECTION (Without Ride height spec.)

For normal vehicles without Ride height specifications, click alignment specification button to see the vehicle specifications. Vehicle parameters are grouped as

(i) Primary angles as shown below:

Fig. 48

(ii) Secondary angles as shown below:

Fig. 49

Ref.: CCDWA - OM 43

Required specifications for the particular model can be viewed by selecting respective options.

Press NEXT SCREEN to go to Customer data input screen (Refer Chapter 7.4.1.3).

7.4.1.2 RIDE HEIGHT BASED VEHICLE SELECTION

Most of the International vehicle specifications prescribed by the Manufacturers are dependent on Ride height measurement. Variations in ride height may alter required specifications.

For vehicles with Ride height specifications, following Ride height input screen will be displayed:

Fig. 50

Measure the points shown in the Car illustration and enter the height in the respective boxes.

If the ride height values are not entered or not within manufacturer's specified range, following message screen will be displayed:

Ride height input is very important. If the input is skipped, the entire alignment specification will go wrong

Press NEXT SCREEN to go to Customer data input screen.

Ref.: CCDWA - OM 44

7.4.1.3 CUSTOMER DATA INPUT

After Vehicle selection, following screen will be displayed.

Fig. 51

Enter the required input.

All the above data will be recorded in the Alignment report which can be taken from the printed after completing the alignment.

System will not proceed further without input of Vehicle Registration number in Customer data input screen

Customer data or Vehicle specifications can be edited or selected respectively between "Initial measurement completed" and "Alignment completed" screens

Press NEXT SCREEN after entering all the data to go to Vehicle Inspection screen.

7.4.2. VEHICLE INSPECTION

Vehicle inspection is not a mandatory process during alignment. However this is a selectable feature to provide value added service

The different parameters for Pre-alignment, Tyre, Brake, Under hood, Under car & General conditions for the Vehicle will be displayed in this window.

Fig. 52

Ref.: CCDWA - OM 45

Fig. 53

Fig. 54

Fig. 55

Fig. 56

Ref.: CCDWA - OM 46

Fig. 57

Check the condition of each parameter for the Vehicle and select the required data to record in the Alignment report.

Press NEXT SCREEN button to Wheel Runout screen. Press PREVIOUS SCREEN button to go back to previous screen.

7.4.3. WHEEL RUNOUT

The purpose of this program is to find out the Wheel Runout (wobbling) and effect the "Runout compensation" automatically in the subsequent programs while Camber and Toe are measured / adjusted.

While doing Runout, do not jerk the Vehicle or the Arms which may cause abnormal Runout

The following screen will be displayed if pre-loading is not necessary:

Fig. 58

Following screen will be displayed if the Vehicle requires pre-loading as specified in the Alignment specification. Load the amount of weight at indicated locations as displayed in the screen:

Ref.: CCDWA - OM 47

Two types of Runout measurement are available in our alignment program as given below:

1. Push-Pull Runout method (Rapid Runout)

Push-Pull Runout is a simple way to measure the Runout of the wheel in a very shortest time by just pushing or rolling the vehicle as guided by the screen. Runout of all the wheels will be captured simultaneously and compensated in the wheel alignment process.

In PPR models, User the option to choose either Push-Pull Runout or Four Point Runout method by toggling the RUNOUT button. The Runout method adopted during previous alignemnt will be displayed by default

2. Four Point Runout method

In Four Point Runout, Vehicle should be jacked up & Wheel runout to be measured individually for every 90° of rotation as guided by the screen.

Four Point Runout method is a selectable feature in PPR models. For other models Four Point Runout is alone applicable

7.4.3.1 PUSH-PULL RUNOUT METHOD (applicable only for PPR models)

Lock the Rotary plates with Locking pins before parking the Vehicle over the Rotary plate

Ensure the Vehicle is in neutral position with Hand brake released

Place Wheel chocks before & behind Front & Rear wheels to arrest excessive movement of vehicle

While moving the vehicle in Forward / Backward direction as guided by the screen, DO NOT move the vehicle beyond the target region to avoid from rolling off. Manufacturer is not responsible for any damage or loss due to non-compliance

During Push-Pull Runout, DO NOT switch ON the engine which will give wrong Runout measurement

Press NEXT SCREEN button to proceed.

Fig. 59

Ref.: CCDWA - OM 48

Press RUNOUT key in Sensor arm keypad or START RUNOUT button to start Push-Pull Runout measurement.

Fig. 60

Push the vehicle backward until ball matches with target region. Following screen will be displayed:

Fig. 61

Once the data is acquired, bring back the Vehicle to the centre of the Rotary plate as guided in the following screen to match target region:

Fig. 62

Then the system will acquire data for compensating Runout.

To redo Runout, press PREVIOUS SCREEN button. Otherwise proceed further. After measuring Runout, tighten the Sensor arm knob.

Tighten the Sensor arm knobs once the Runout measurement is completed

Ref.: CCDWA - OM 49

7.4.3.2 FOUR POINT RUNOUT METHOD

Make the Gear lever to Neutral position if the vehicle being aligned is Rear wheel drive

Remove the Locking pins in the Rotary plates and apply Brake pedal lock before jacking down

Loosen all the Sensor arm locking knobs before Runout measurement

Press NEXT SCREEN button to proceed.

Press RUNOUT key in Sensor arm keypad or F1 key for Four Point Runout measurement.

Rotate the wheel in CLOCKWISE direction as indicated by the Flashing Arrow and bring the Bracket knob to 90°. Hold the Arm in Horizontal position and press RUNOUT key. Rotation of the wheel should be done only when the Arrow blinks. Otherwise the Runout values will be wrong.

Fig. 63

Do the above procedure for 180°, 270° & 360° respectively and now Runout is completed. Completion of Runout will be indicated by a Tick mark over the respective wheels.

After each activity of Runout, either RUNOUT key available in Arm keypad can be pressed or F1 (for left Runout) & F7 (for Right Runout) button in Alignment screen can be pressed

If any of the wheels are abnormal, press REDO RUNOUT (Arrow indication) to redo Runout for the particular wheel. To redo Runout for all wheels, press PREVIOUS SCREEN button. Otherwise proceed further. After measuring Runout, tighten Sensor arm knob.

Tighten the Arm knob in Horizontal position.

After the data is acquired, bring back the Vehicle to the centre of the Rotary plate and follow the on-screen instructions.

Fig. 64

Ref.: CCDWA - OM 50

Lower the Wheel & apply Hand brake. Jounce the vehicle to free up the joints.

Apply Brake pedal lock and remove the Rotary plate & Slider locking pins and then jounce the vehicle. Ensure the level of Sensor arms using spirit bubble.

Press HELP button to get Help

Press PREVIOUS SCREEN to go back to previous screen

Press WELCOME SCREEN button to go to Home screen

Press NEXT SCREEN to go to next program.

Tighten the Sensor arm locking knobs once the Runout measurement is completed

Remove the Locking pins from Rotary plate once the Runout measurement is completed

7.4.4. CASTER & KINGPIN SWING

Caster and Kingpin angles are differential angles and cannot be measured directly. Hence a sequence of procedure is required to measure the parameters.

Do not jerk or shake the Steering wheel during data acquisition

Hold the Steering wheel at the end of each move to acquire stable measurement of Caster / Kingpin. Do not rush into turns

During Left turn/Right turn/Straight Ahead, if there is any obstruction of light beam between the Sensor arms, an error screen with No video signal message will be displayed until the error is cleared

While working on Power steering vehicles, switch ON the engine before fixing the Steering wheel lock in Straight ahead position (ensure that Gear is in neutral position). The engine may be switched "OFF" after Straight ahead is completed

7.4.4.1 ARMS HORIZONTAL

Fig. 65

This screen is meant to instruct the User to make Sensor arms horizontal and delivers the simulation of Arm movements in the Wheel bracket. When the Arms are made to perfect horizontal position, the Arm tubes in the Screen will be in GREEN color (ie., 0 or upto ±10 minutes). If RED color is seen, move the Arms up or down till the color changes to GREEN.

Ref.: CCDWA - OM 51

After making the Arms horizontal, lock them firmly using the Arm knobs. In the same screen, Camera status will be displayed. If the camera path is obstructed by some objects, status bar of that Camera will be displayed in Red color. In such case, choose the Spoiler option to lower the arms equally down until the Status bar glows in Green color.

Before doing Arms Horizontal, ensure that the wheels are more or less straight ahead

Ensure that the Brake pedal lock has been fixed properly

Tilting of Arms downwards upto -3º 30' equally will not affect the measurement.

Ensure that the Camera status is in Green color. If it is in Red color, then the camera path is obstructed.

Lock Arm knobs firmly after achieving equal readings & both Camera status are in Green.

7.4.4.2 TOE OUT ON TURNS & LOCK ANGLE MEASUREMENT (Optional feature using Mechanical Rotary plate with Angle indicator)

The TOT/LA button will be displayed in the screen only if the Optional feature is enabled and operated using Mechanical Rotary plate with Angle indicator

Press TOE OUT TURNS / LOCK ANGLE button and key-in the initial Rotary plate scale values in the respective box as shown below:

Fig. 66

Press NEXT SCREEN button. Readings will be displayed as shown below:

Fig. 67

Press NEXT SCREEN button to go to Turn Left screen.

Ref.: CCDWA - OM 52

7.4.4.3 TURN LEFT

Fig. 68

In this screen, a Steering diagram can be seen and a Flashing arrow will indicate the direction in which the wheel is to be turned.

Steer the wheels to left until the moving BALL fully matches the left GREEN region. After reaching the Left Green region, the system will display "Stop " icon and measures the parameters. After data acquisition, system will automatically go to Turn Right screen.

7.4.4.4 TURN RIGHT

Fig. 69

Steer the wheels to right until the moving BALL fully matches the right GREEN region. After reaching the Left Green region, the system will display "Stop" icon and measures the parameters. After data acquisition, system will automatically go to Straight ahead screen.

7.4.4.5 STRAIGHT AHEAD

Fig. 70

Ref.: CCDWA - OM 53

This screen is to instruct the User to bring the Front wheels to Straight ahead position. Steer wheels until the moving BALL fully matches the centre GREEN region.

When Straight ahead position is achieved, "Stop" symbol will appear and stop turning the Steering wheel.

If the Straight ahead is disturbed, the symbol will vanish and the arrows will blink and guides to indicate in which direction to turn the Steering wheel to get back the Straight ahead position.

Now adjust the Steering wheel straight manually for fine adjustment till the Red ball in the Green region reaches the centre white region, followed by a "Stop" symbol and then goes to next screen.

Fig. 71

Lock the Steering wheel in straight position visually and then press NEXT SCREEN button to view the Alignment results of existing condition of the vehicle in Live mode.

Fig. 72

In Straight ahead condition, If horizontality of any one of both Sensor arms are disturbed after fixing the Steering lock, system will automatically prompt the operator to make the "Arms horizontal" and press NEXT SCREEN button. System enters into Straight ahead screen

Ref.: CCDWA - OM 54

7.4.5. ALIGNMENT PARAMETERS & RESULTS

Following procedure needs to be carried out for the adjustments as per Manufacturer‟s specification

First perform Camber correction and then do Toe correction

TWO COLOR REPRESENTATION

While doing Caster, Camber & Toe correction, pointing Arrow sliding over the Horizontal bar indicates specification range using different colors as indicated below:

Color Indication

Red Reading is not within required specification.

Green Reading is within specification & preferred value

White Specification is not available / required for parameter

A Spanner image displayed over the Parameters image means it is adjustable. Hence by clicking the Spanner image, an animated movie or sketch to explain the adjustment methods of alignment parameters can be viewed as shown below:

In case if the Spanner image is crossed, parameter is not adjustable

Initial measurement results of existing vehicle condition will be displayed:

Fig. 73

Printout of the measurement results can be taken by pressing PRINT button.

Press NEXT SCREEN button to go to Rear wheel parameters screen.

Ref.: CCDWA - OM 55

7.4.5.1 REAR WHEEL PARAMETERS

By pressing REDO ALIGNMENT button, complete alignment sequence from Wheel runout screen can be repeated

Fig. 74

In this screen, Live readings of Rear wheel Camber and Toe will be displayed. Effect the corrections in the Rear wheels until the GREEN color at the Horizontal bar with the Arrow point to that region.

In case of alignment using Lift, compensate the uneven level in the Lift platform by pressing LEVEL COMPENSATION PROGRAM button. The following screen will appear to raise the lift to adjustable position:

Press NEXT SCREEN button to return to Rear wheel parameters adjustment. Then proceed with Front wheel parameters adjustment procedure and finally by pressing LEVEL COMPENSATION button again, following screen will be displayed to lower the Lift as shown below:

Result printout can be taken during the Level compensation program or even after lowering the Lift platform. Press NEXT SCREEN button to go Front wheel parameters screen

In case of any specific adjustments needs to be done, press ADJUSTMENT TYPES button for On-screen guidance for Camber and Toe in Wheel raised condition (refer chapter 7.4.5.4).

Tighten the Lock nuts.

Ref.: CCDWA - OM 56

Press ADDITIONAL PARAMETER button to view Rear wheel Total Toe & Thrust angle as shown in the Rear wheel parameters screen.

Fig. 75

Press ADDITIONAL PARAMETER button to view the Rear Wheel Setback & Track width difference as shown in the following screen (This features is applicable only for Premium Plus models).

Fig. 76

The Track width difference will be displayed as Positive angle, if the Rear Track width is more than the Front Track width and as negative angle if the Front Track width is more than the Rear Track width.

Press PREVIOUS SCREEN to return to the Rear Wheel parameters correction screen.

During Rear wheel Toe correction, if any obstruction exists in between the two Sensor arms, following "Attention" screen will appear until the error is cleared. Otherwise alignment cannot be proceeded further

Ref.: CCDWA - OM 57

By clicking the Parameters image in the centre of screen, a zoomed image of the respective reading will be displayed

NEXT key in Sensor arm keypad can be used to view next

screens. PREV key can be used to escape from Zoom option

After adjustment of Rear wheel parameters, press NEXT SCREEN button to go to Front wheel parameters screen.

7.4.5.2 FRONT WHEEL PARAMETERS

By pressing REDO ALIGNMENT button, complete alignment sequence from Wheel runout screen can be repeated

Fig. 77

This screen displays the Live readings of Caster, Camber and Toe. Effect the corrections in the Front wheels until the GREEN color at the Horizontal bar with the Arrow point to that region.

In case of any specific adjustments needs to be done, press ADJUSTMENT TYPES button for On-screen guidance for Camber and Toe in Wheel raised condition (refer chapter 7.4.5.4).

Press ADDITIONAL PARAMETER button to view Kingpin, Runout & Setback values. Out of these three, Runout & Setback are having compensation with Camber and Toe respectively.

Fig. 78

Ref.: CCDWA - OM 58

In case of Toe Out on Turns & Lock Angle measurement is opted during Caster & Kingpin swing sequence, following

screen will be displayed:

Key-in the final Rotary plate scale values after adjustment (as explained in Chapter 7.4.5.4) in the respective box and the final readings will be displayed

By clicking the Parameters image in the centre of screen, a zoomed image of the respective reading will be displayed

NEXT key in Sensor arm keypad can be used to view next screens. PREV key can be used to escape from Zoom option

While adjusting Caster, Toe may get slightly affected. Similarly, while doing Camber & Toe, since both are Wheel angles, one may get affected while adjusting the other. Therefore, ensure all angles are ‘OK’ before locking Lock nuts & completing alignment. Otherwise, do some finer adjustments to get everything ‘OK’

During Caster, Camber & Toe correction, if any obstruction exists in between two Sensor arms, following "Attention" screen will appear until the error is cleared. Otherwise alignment cannot be proceded further.

For Caster correction, adjust the Caster by the method specified by manufacturer

Ref.: CCDWA - OM 59

Live Caster is measured by detecting forward and backward rotation of wheel. For that, it is important the arms are not disturbed. If any mistake is done during this activity, you may get wrong Caster values. To verify, press REDO CASTER button to redo the Caster measurement again. Then proceed to steps explained in Chapters 7.4.4.3, 7.4.4.4 & 7.4.4.5 to get the Caster values. System will come to Front wheel parameters screen & will display new values of Caster

If Toe value to be displayed mm mode, click the mouse pointer on the MM selector and feed the diameter of the RIM size in inches. The display will be changed to mm. If the display is to be changed to degree mode again, click on the Deg selector

On cars with Rack and Pinion steering, a bump steer condition is usually created by worn rack mounting bushings that allow the entire rack to shift when bumps are hit. Some vehicles have slotted Idler arm mounts to allow correction of Toe curve change problems

In certain Cars where suspension work is done, Front wheels may have excessive Toe setting. This may lead to problems in achieving Straight ahead position. Operator is alerted as shown below:

The procedure to be adopted in such a situation is to first bring the Steering wheel to Straight ahead position and lock it in that position using Steering wheel lock. Then proceed with adjustment & set the required Toe in a single operation. In cases where there is no excessive Toe, there is no change in the procedure

During adjustment, when large corrections are made to Caster, Camber or Toe, the Arms horizontality may get disturbed in most cars. This results in inaccurate Toe setting, since it is one parameter which depends very much on how well the Arms are kept in horizontal position.

The Operator is alerted if such a situation arises by displaying a message that the Arms horizontal has been disturbed when NEXT SCREEN button is pressed after correcting all the parameters.

Values in Horizontal bars are minimum & maximum values of the corresponding Wheel parameters.

This message is shown only in conditions when the horizontality of any or both Arms are lost by more than 20 minutes. The Operator is advised to make the Arms horizontal and re-adjust the Toe to required values

Press NEXT SCREEN to complete alignment & go to Results screen.

Ref.: CCDWA - OM 60

7.4.5.3 RESULTS

Data from alignment results are forwarded to the Wheel aligner Data Manager only when HOME button is pressed at the end of wheel alignment in Alignment completed screen

The following Reports are provided to print the alignment results:

1. Standard printout - Results of Camber, Caster, Kingpin, Toe, Thrust angle & Setback

Fig. 79

2. Additional printout - Results of Toe Out on Turns, Lock Angle and Tyre & Bearing conditions

3. 3D printout - Pictorial representation of Camber, Caster, Kingpin, Toe, Thrust angle & Setback

Fig. 80

4. Pre-alignment inspection report - Present condition of Vehicles recorded and stored

5. Tyre inspection report - Present condition of Tyre recorded and stored

6. Brake inspection report - Present condition of Bake & related parts recorded & stored

7. Under hood inspection report - Present condition of Vehicle Under hood components recorded & stored

8. Under car inspection report - Present condition of Vehicle Under car parts recorded & stored

9. General inspection report - Present condition of Vehicle lightings & fittings recorded & stored

Printout of the Alignment results can be viewed or printed by pressing PRINT button.

PDF file can be created and stored in the system using the SAVE TO PDF icon.

Ref.: CCDWA - OM 61

Press HOME button and then select TICK mark to forward the alignment reports to Data Manager program and return to Welcome screen as shown below:

Fig. 81

This completes the Four wheel alignment.

7.4.5.4 ADJUSTMENT TYPES The adjustment of vehicle parameters may vary depending upon the vehicle construction. Following adjustment types are provided:

Fig. 82

Single Tie rod adjustment

Toe curve adjustment

Elevated Front & Rear Caster/Camber/Toe

Elevated Front Camber

Elevated Rear Camber

Ref.: CCDWA - OM 62

1. SINGLE TIE ROD ADJUSTMENT

Some of the earlier design of trucks and 80‟s generation of vehicle have a single tie adjuster for Total Toe with no provision for adjusting steering direction. For these type of vehicles, select SINGLE TIE ROD ADJUSTMENT button and follow the procedure given below:

Steer the Front wheels to bring the Toe reading to zero. Lock the Steering wheel at this position. Once zero reading is achieved, Total Toe readings will appear on top window.

Fig. 83

Adjust the Single tie rod to Total toe specifications displayed.

If Steering straight ahead is still not achieved, remove Steering wheel from the steering column (see Vehicle recommended procedures prior to removal) and re-fix it properly.

2. TOE CURVE ADJUSTMENT

To measure the changes occur in individual Toe due to jounce/ rebound of suspension. An excessive amount of change in individual Toe may cause early Tyre wear. Excessive change on one side alone may cause the vehicle to rapidly change directions when bumps are encountered.

There are no specifications prescribed by the Manufacturer for the amount of change. The Toe changes should be fairly minimum, and a comparison of Left and Right wheels will assist in diagnosing the defective Steering system components.

Follow the on-screen instructions carefully to raise the suspension to 60mm by pushing down / lifting up the Suspension using a Scale or Measuring tape to observe the proper amount of frame movement :

Fig. 84

Ref.: CCDWA - OM 63

The difference in individual Toe will be displayed as shown below:

Fig. 85

Make the required adjustments / changes to bring down the difference to fairly minimum and then bring the vehicle to normal position.

Fig. 86

3. ELEVATED FRONT & REAR CASTER / CAMBER / TOE

Keep hands & other body parts away from jacking surfaces. Follow jack manufacturer’s safety recommendations. Failure to comply may lead to human injury

While jacking up the vehicle, the vehicle should be stable and do not apply any external force which may shake the vehicle and subsequently the readings will be affected

In certain vehicles, the Left and Right wheels cannot be jacked up simultaneously due to their construction. In such vehicles, the Left and Right wheels have to be jacked up individually and the Camber correction should be performed for both wheels separately as described above

Ref.: CCDWA - OM 64

Following screen will be displayed to jack up the vehicle:

Fig. 87

Press NEXT SCREEN button

Live values of Front / Rear wheel parameters can be viewed by pressing FRONT PARAMETER / REAR PARAMETER button respectively for further adjustment.

By default, Front wheel parameters will be displayed in the screen. The values will automatically be set to the initial values shown when wheels were resting on the Rotary plates or floor.

Fig. 88

Now adjust the Front wheel parameters to achieve the specified value.

To adjust Rear wheels press REAR PARAMETER button. Live values of Rear wheel parameters will be displayed in the screen. The values will automatically be set to the initial values shown when wheels were resting on the Rotary plates or floor.

Fig. 89

Ref.: CCDWA - OM 65

Now, adjust the Rear wheel parameters to achieve the specified value and press NEXT SCREEN button. “Jack down and jounce the vehicle” message will be displayed.

Fig. 90

Values that are adjusted during raised position will be restored.

4. ELEVATED FRONT CAMBER


Fig. 91

Press NEXT SCREEN button.

Live Front Camber values will be displayed in the screen. The values will automatically be set to the initial values shown when the wheels were resting on the Rotary plates or floor.

Fig. 92

Ref.: CCDWA - OM 66

Now, adjust the Front Camber to achieve the specified value and press NEXT SCREEN button. Then “Jack down and jounce the vehicle” message will be displayed:

Fig. 93


5. ELEVATED REAR CAMBER


Fig. 94

Press NEXT SCREEN button.

Live Rear Camber values will be displayed in the screen. The values will automatically be set to the initial values shown when the wheels were resting on the Rotary plates or floor.

Fig. 95

Ref.: CCDWA - OM 67

Now, adjust the Rear Camber to achieve the specified value and press NEXT SCREEN button. Then “Jack down and jounce the vehicle” message will be displayed:

Fig. 96


7.5. QUICK WHEEL ALIGNMENT

Quick wheel alignment can be performed only in LCVs and HCVs with single rear axle

Quick wheel alignment refers to alignment of a vehicle in the shortest possible time. The normal alignment sequence is shortened by skipping some of the steps and Attention screens in the alignment process and keeping only the required process.

User can customize the program sequence to their preference as explained in Quick wheel alignment settings (Refer Chapter 8.1 of Service manual). Later, based on the requirement user can choose the particular customised alignment program to proceed with Quick wheel alignment.

Ref.: CCDWA - OM 68

7.6. DATA MANAGER

This software will work only on Wheel aligner machine

Data from alignment results are forwarded to the Wheel aligner Data Manager only at the end of wheel alignment in the Alignment completed screen

Data Manager is smart software developed for the purpose of managing alignment results which are generated by Wheel aligner. This software runs under Windows platform and provides menu driven, user friendly Graphical User Interface.

This software is designed to retrieve the stored alignment results and to generate reports. The following screen is the Opening screen of this software.

Fig. 97

Four options will be displayed: 1. Date based Alignment report 2. Registration Number based Alignment report 3. Year based Alignment report 4. Technician based Alignment report 5. Customer database 6. Reminder to Customer

7.6.1. DATE BASED ALIGNMENT REPORT Upon selection of Date based Alignment report, a Date window will appear:

Fig. 98

Select the required “From” and “To” date between which Alignment results have to be viewed and press NEXT SCREEN button.

Ref.: CCDWA - OM 69

Following screen will be displayed:

Fig. 99

Fig. 100

The list of alignments conducted within the provided date will be displayed Job number wise. By selecting "Front" / “Rear” tab in the screen, results of respective wheel parameters can be viewed.

Press VIEW button to view the Date based reports as shown below:

Fig. 101

Press PRINT button to print the report.

Ref.: CCDWA - OM 70

7.6.2. REGISTRATION NUMBER BASED ALIGNMENT REPORT This report helps the user in deciding the frequency of the alignment made for the selected vehicle.

Upon selection of Registration number based Alignment report icon, a Pull down list of Vehicle Registration Numbers for which alignment carried out so far will be displayed as shown below:

Fig. 102

Select the required Vehicle Registration number and press NEXT SCREEN button. Following screen will be displayed:

Fig. 103

Fig. 104

The list of alignments conducted for the selected Vehicle registration number will be displayed based on Job number. By selecting "Front" / “Rear” tab in the screen, results of respective wheel parameters can be viewed.

Ref.: CCDWA - OM 71

Press VIEW button to view Registration No. based reports as shown below:

Fig. 105


7.6.3. YEAR BASED ALIGNMENT REPORT Upon selection of Year based alignment report icon, a Pull down list of year for which alignment carried out so far will be displayed as shown below:

Fig. 106

Select the required Year and press NEXT SCREEN button.

Press VIEW button to view the Year based alignment report as shown below which helps the user in getting the No. of alignments achieved in a year (Month wise):

Fig. 107


Ref.: CCDWA - OM 72

7.6.4. TECHNICIAN BASED ALIGNMENT REPORT Upon selection of Technician based alignment report icon, the available User‟s list will be displayed:

Fig. 108

Select the required User, ”From” & “To” date and then press NEXT SCREEN button. Then press VIEW button to view the number of alignments (consolidated) conducted by the selected User as shown below:

Fig. 109

Operator can also choose ALL USER to view the number of alignments (consolidate) conducted by each user


7.6.5. CUSTOMER DATABASE Upon selection of Customer database icon, a Date window will be displayed. Select the required “From” and “To” date and press NEXT SCREEN button:

Fig. 110

Ref.: CCDWA - OM 73

Press VIEW button to view the date based Customer details as shown below:

Fig. 111


7.6.6. REMINDER TO CUSTOMER This option is provided to the user to generate Reminder letters to his customers on daily basis. The system followed is, when he runs this option on a particular date, the system will automatically generate Reminder letter for the vehicles aligned exactly 90 days back.

Fig. 112


Press HOME button and then select TICK mark to exit from Data Manager program and return to Welcome screen as shown below:

Fig. 113

Ref.: CCDWA - OM 74

7.7. SETTINGS You can enter into this Option by clicking SETTINGS in the Welcome Screen and by providing the Password.

Fig. 114

The following Menu will be displayed:

Vehicle

specifications Ref. Chapter 7.7.1

Measurement units

Ref. Chapter 7.7.2

Restore calibration

data Ref. Chapter 7.7.3

Quick wheel

alignment settings Ref. Chapter 8.1 of

Service manual

Push-Pull Runout (PPR) calibration

Ref. Chapter 7.2 of Service manual

Workshop information

Ref. Chapter 7.7.4

Passwords

Ref. Chapter 7.7.5

Calibration history

Ref. Chapter 7.7.6

RF Channel setting

Ref. Chapter 8.2 of

Service manual

Electronic Rotary plate calibration

Ref. Chapter 7.3 of Service manual

User Login

Ref. Chapter 7.7.7

Arm communication

check Ref. Chapter 7.7.8

Calibration certificate

Ref. Chapter 7.4 of

Service manual

Sensor arm board ID

setting Ref. Chapter 8.3 of

Service manual

Four shaft calibration

Ref. Chapter 7.1.2 of Service manual

Reset Job number

Ref. Chapter 7.7.9

Testing options

Ref. Chapter 7.7.10

Camera testing

Ref. Chapter 8.4 of

Service manual

Left/Right Steering

wheel setting Ref. Chapter 8.5 of

Service manual

Single shaft calibration

Ref. Chapter 7.1.1 of Service manual

Ref.: CCDWA - OM 75

7.7.1. VEHICLE SPECIFICATIONS

The Vehicle specification data must be entered by End user only. MANUFACTURER IS NOT RESPONSIBLE FOR ANY INCORRECT OR INCOMPLETE VEHICLE SPECIFICATIONS ENTERED / AVAILABLE IN THE SYSTEM. No claim is entertained for any damage or loss

Fig. 115

7.7.1.1 EUROPEAN / BRAZILIAN / UNITED STATES VEHICLE DATA

Fig. 116

The readily available vehicle specifications that are compiled and released by Third parties with License can be directly uploaded in our system. These vehicle specifications are updated & released twice every year at extra cost. These data are non editable but the User can select the required vehicles from the list & export it by pressing EXPORT TO USER DATA button to User data for edit & customizing the specification.

Vehicle data can be exported to User data for modifying the data while doing alignment for customised vehicles

7.7.1.2 INDIAN VEHICLE DATA The Indian data contains specifications of known vehicles collected by Manufacturer with update available at the time of despatch. However Manufacturer is not responsible for any incorrect or incomplete vehicle specifications available in the Indian data.

Ref.: CCDWA - OM 76

7.7.1.3 USER DEFINED VEHICLE DATA The vehicle specifications collected by the User can be added / modified / viewed using this option as given below:

Fig. 117

Following options are provided:

Add specification - To add new Vehicle specifications

Edit specification - To modify the existing vehicle specifications

Delete specification - To delete the existing vehicle specifications

Select the required options based on specifications to be entered:

Fig. 118

For HCV vehicles, specification for all the wheels will differ, In such case, Individual specifications option can be selected

COMMON SPECIFICATIONS (LEFT / RIGHT)

By selecting this option, screen displays the following Data sheet in which the details of specifications are to be filled:

Fig. 119

Ref.: CCDWA - OM 77

The user has to keep ready all these information before starting to add any Vehicle specifications.

1. VEHICLE MAKE

Type Vehicle make and press ENTER to go to the next window.

2. VEHICLE MODEL

Type Vehicle model and press ENTER to go to next window.

3. TOE IN DEGREES / MM / INCHES (D,M,I) ?

The TOE values of the vehicle can be entered in “degree” (or) “mm” (or) “inch”. To intimate the system about the TOE input unit, enter "D" for Degrees, "M" for mm and "I" for inches. Press ENTER to move to next window. This window cannot be left blank. A beep sound will be heard it attempted.

4. RIM DIAMETER

If the Toe unit is entered as “mm” or “inch”, then the Rim Diameter of the vehicle has to be entered. If this window is not filled, the system will not allow you to proceed further.

Alignment specifications

Each and every angle has been provided with four data entry windows. First two for the Front` wheels and other two for Rear wheels. Two windows are given for each wheel to enter the Maximum and the Minimum permissible reading.

5. CASTER

Enter the Minimum allowable Caster for that vehicle in first data window. Enter the Maximum allowable Caster in second window. As Caster is not applicable for Rear wheels, system will prompt "N/A" in the other two Rear wheel windows, so you can't enter any data in these windows.

6. KINGPIN

Follow the same procedure as done in Caster. Kingpin is also not applicable for Rear wheels, so "N/A" will be displayed in the Rear wheel windows.

7. CAMBER

Enter Camber readings as per procedure for both Front & Rear wheels.

8. TOE

There are three options for entering Toe readings. Any one of the options can be chosen according to the requirement. i.e., if 'D' is entered in "Toe in degree / mm / inch (D,M,I) ?" Data window, then Cursor will be taken to Toe in Degrees Data window.

If "M" is entered, then the cursor will be placed in the Toe in MM data window and for "I", it will be Toe in Inches data window. The windows other than the selected will have "----" in them.

9. TOTAL TOE

For some vehicles only Total Toe values are only known. In that case, enter the readings in these windows. Here also three options are provided as in the case of Toe.

If the Toe / Total Toe values are entered in "mm" "Inches", the system will convert it to "degree & minutes"

If Toe values are entered first, then Total Toe will be calculated by the system itself from the entered Toe value & displayed in Total Toe window and vice versa if Total Toe value is entered first

Ref.: CCDWA - OM 78

INDIVIDUAL SPECIFICATIONS (Left / Right) (only for HCV vehicles)

To add new specifications, select "Add Make/Parameter" as below:

Fig. 120

The screen displays the above Data sheet in which the details of specifications are to be filled. The user has to keep ready all these information before starting to add / modify any Vehicle specifications.

7.7.2. MEASUREMENT UNITS This option is used to change the measurement units like “degree min" / “degree” / “mm" / “inch” and other angles in “degree” / “degree min”, “kg” “lb”

Fig. 121

7.7.3. RESTORE CALIBRATION DATA This option is provided to backup / restore the Calibration data between alignment units & external devices, if the existing files are modified or corrupted or in case of re-installation.

Following are the options provided:

Fig. 122

Ref.: CCDWA - OM 79

7.7.3.1 BACKUP CALIB DATA FROM PC TO SENSOR ARM This option is used to backup the Calibration data from Desktop Computer to Sensor arms

A backup is stored in local HDD of Personal computer.

Fig. 123

Select the respective Sensor arm in which the data backup is to be done and click SAVE button. After taking backup, a tick mark will appear in the respective Sensor arm.

7.7.3.2 RESTORE CALIB DATA FROM SENSOR ARM TO PC This option is used to restore the Calibration data from Sensor arms to Computer.

Fig. 124

Select the respective Sensor arm from which the calibration data is to be restored and click SAVE button. After restoration, a tick mark will appear in the respective Sensor arm.

7.7.3.3 RESTORE FACTORY CALIBRATION DATA TO PC This option is used to restore the original Calibration data from the Optical media provided by Manufacturer to Desktop Computer.

The system will prompt to locate the source of calibration files for restoration. Files are provided along with Aligner in an Optical media format. Also a backup is stored in local HDD of Personal computer.

Fig. 125

Ref.: CCDWA - OM 80

7.7.3.4 BACKUP CALIB DATA FROM PC TO OTHER LOCATION/DEVICE This option is used to backup the Calibration data, User defined vehicle data, International vehicle data, User settings & Data Manager from Desktop computer to other locations in the HDD or other external devices like USB drive or Optical media.

Choose the location in which data is to be saved & click SAVE button.

7.7.3.5 RESTORE CALIB DATA FROM OTHER LOCATION/DEVICE TO PC This option is used to restore the Calibration data, User defined vehicle data, International vehicle data, User settings & Data Manager from other locations in the HDD or other external devices like USB drive or Optical media to Desktop computer.

Choose the location from which data is to be restored & click SAVE button.

7.7.4. WORKSHOP INFORMATION This Option is used to enter the Customer Name and address of the Alignment Centre and password settings. Customer can also add Logo of their Service centre to appear on the top left corner of the printout.

Fig. 126

After entering the data, click SAVE button on the screen to save the data.

7.7.5. PASSWORDS This option is provided to activate the optional features from field and to reset the User password: The Optional features available in alignment programs are controlled using built-in hardware lock. The user himself can activate the required Optional feature by paying additional cost and sending the Hardware lock number along with Machine Serial Number to Manufacturer. Upon receiving the key code from Manufacturer, select the respective feature in the screen and enter the Key code and then press SAVE button.

Following are options provided, if Passwords is selected from Settings menu:

Fig. 127

Ref.: CCDWA - OM 81

7.7.5.1 SETTINGS PASSWORD

This option is provided to set password for accessing the settings.

Fig. 128

Current password will be displayed. User will be prompted to enter the new password. If password is correct, the operator will then be prompted to enter the New password again for confirmation

If the re-entered password is not correct, "Re-enter. Password does not match" message will be displayed

After re-entering the new password correctly, click SAVE to save the password (Factory set default password is "supervisor").

7.7.5.2 VEHICLE DATA PASSWORD

This option is provided to activate the International Vehicle data that are compiled & released by Third parties with License. These vehicle specifications are updated & released twice every year at extra cost.

Fig. 129

This screen will display the status and then the Year of Vehicle data update available in the system. To activate Vehicle data for the displayed year, User can purchase the key code from Manufacturer for that particular year & key-in for activation.

Ref.: CCDWA - OM 82

In case if User prefers to get the latest update available as of date, first install the purchased vehicle data software as explained in Chapter 6.2 (software installation) of Service manual and then enter the key code provided along with the software and press SAVE button.

Fig. 130

If the customer operates recently purchased Aligner (loaded with latest vehicle data) with an old RF unit, user can either purchase/ provide the Key code for that latest update and activate the same or install the RF unit compatible Vehicle data software & activate it.

Fig. 131

Fig. 132

Ref.: CCDWA - OM 83

7.7.5.3 ELECTRONIC TURN TABLE (ERP) PASSWORD

This option is provided to activate the measurement of Toe out On Turns and Lock Angle for Front wheels using Electronic Rotary plate.

Fig. 133

This screen will display the status of availability. In case of activation, User will be prompted to enter Key code obtained from Manufacturer.

7.7.5.4 RAPID / PUSH-PULL RUNOUT (PPR) PASSWORD

This option is provided to activate the Push-Pull Runout feature.

Push-Pull Runout feature is set at Factory itself for PPR models

Fig. 134


7.7.5.5 MECHANICAL TURN TABLE (with Angle indicator) PASSWORD

This option is provided to activate the measurement of Toe out On Turns and Lock Angle for Front wheels using Mechanical Rotary plate with Angle indicator.

Fig. 135


Ref.: CCDWA - OM 84

7.7.6. CALIBRATION HISTORY The details of calibration done so far can be viewed in Calibration history.

Fig. 136

To take a printout, press PRINT button or to save it in the system, press SAVE TO PDF icon in the screen.

7.7.7. USER LOGIN This option is used to create User accounts to operate the system. In this user can also edit or delete the existing accounts.

Fig. 137

7.7.8. ARM COMMUNICATION CHECK This Option is provided to check & ensure the communication between the Sensor arms and Computer.

Fig. 138

The data communication can be viewed by pressing the relevant Sensor arm and enabling the Sensor data option. The status of the communication trials will be displayed in the Status window.

Ref.: CCDWA - OM 85

7.7.9. RESET JOB NUMBER Job Number is a Serial number which is automatically generated by system for each alignment job. This option is useful to reset the Job number to 0001. If this option is selected, confirmation will be requested to reset Job Number. If YES is selected, Job number will be reset. Press NO to skip current operation.

Fig. 139

7.7.10. TESTING OPTIONS This option is provided to test the functions of Sensor arm keypad and Buzzer.

Fig. 140

7.7.10.1 KEYPAD TESTING

The function of Sensor Arm keys in the keypad can be tested by pressing the keys and the respective key will blink in the screen.

Fig. 141

Ref.: CCDWA - OM 86

7.7.10.2 BUZZER TESTING

Buzzer function can be tested by selecting the respective Sensor arm in the screen and audio can be heard from the respective arm.

Fig. 142

7.8. LANGUAGE SETTINGS The User can select the prefered language out of the available options so as to display the alignment screens and Voice prompts in their regional languages. Press LANGUAGE button in the Welcome screen and select the language as shown below:

Fig. 143

After setting the language, press SAVE button

Ref.: CCDWA - OM 87

8. MAINTENANCE

Turn OFF the MCB switch and unplug the Aligner before doing any maintenance or repair work

The equipment requires only minor maintenance to keep the equipment operating properly.

We recommend attention to the following points for getting maximum benefit out of the equipment.

1. Keep the area around the Aligner clean. Remove any tools or other items that are leaning against the Aligner.

2. Use only recommended Accessories / Spares. Accessories from other manufacturer may not fit or function properly and may damage the equipment.

3. For continuous protection against fire hazard replace the Control fuses only with same type and rating of CE marked Fuse.

Control fuse F1 – 3A, Dia 5 mm x 20 mm, Slow blow type Glass fuse

Control fuse F2 – 5A, Dia 6.35 mm x 31.8 mm, Slow blow type Glass fuse

Control fuse in Sensor arm – 1A, Dia 5 mm x 20 mm, Slow blow type Glass fuse

4. Protect the System from direct sunlight.

5. Do not attempt to open the System cabinet / Interface box / Sensor arms for any reason as you may spoil the Electronic circuit and components. In case of any fault, please call Service Engineer.

6. Clean the System once or twice a day using a soft cloth. DO NOT wash the system using Water.

7. Clean the visible glasses in the Sensor arms regularly using a soft cloth.

8. Clean the Sensor arm Keypad / Keyboard with Non-solvent, Non-abrasive cleaner. DO NOT use cleaning agent which attacks the keypad and could result in equipment damage.

9. Protect the Rotary plates from dust. Foreign particles / dust may affect the rotation, leading to wrong Caster / Kingpin readings. Service the Rotary plates once in 3 months.

10. Clean the Wheel Brackets periodically and lubricate for smooth functioning.

11. DO NOT try to charge the batteries with any other Charging equipments.

12. Replace the Batteries only with same Volts and current ratings.

Specifications: Type : Valve regulated Lead Acid

Volts : 6.0V

Ampere / Hour : 7.2 AH / 20 Hr

Terminal : Snap on plug type

Dimensions : 125 mm (L) x 32 mm (W) x 60 mm (H)

DO NOT try to clean or disassemble the battery as it could result in the leakage of sulfuric acid resulting in acid burns.

13. Keep the System covered when not in use to avoid dust.

14. Keep the System away from Moisture.

Ref.: CCDWA - OM 88

9. TROUBLE SHOOTING The common troubles and error messages which can be attended by the users are listed in the table given below.

For Troubles and Error messages other than that are listed in the table contact the Service Engineer for Trouble shooting.

The Service Engineer may ask for information to help in diagnosing the service concern. Conveying this information to the Service Engineer prior to servicing can help to expedite service to your equipment

9.1. HARDWARE TROUBLE SHOOTING EQUIPMENT

Sl. No.

Trouble Causes Remedies

1

When System is switched ON, no beep sound and No display

Power socket problem or loose connection in the Power socket plug point

Insert the equipment‟s Power cord to another Plug point‟s power socket & check it

Still problem persists

UPS may be defective. i.e, No output from the UPS

Connect a Test lamp at the output socket of UPS and ensure whether UPS is OK. If not replace the UPS

Loose connection in Fuse / Fuse may be blown off.

Check the status of Fuse and replace it

All the external parameters have been checked. But the display problem remains as it is

ON/OFF Switch or Power supply board may be faulty

Get the problem solved through Service Engineer

2

When equipment is switched ON, only Audio sound is noticed. But no display in Monitor

Monitor may be switched OFF or Power supply to Monitor may got disconnected.

Switch ON the Monitor and Check the Power LED is ON. If not, replace the Power cord.

Monitor Power LED blinking in Standby mode. But no display

Loose connection in the Monitor data cable

Switch OFF the system, remove the 15 Pin data cable and reconnect it to the system with correct polarity

No loose connection in Data cable. Still the display problem persists

Monitor may be defective Replace a monitor from other computer and check for it

Computer‟s Internal system may be defective

Get the problem solved through Service Engineer

3 Electrical Shock observed in the system

No Earthing or loose contact in the Earthing point of switch board

Get the problem solved through Qualified personnel

Earth terminal in Power cord may have intermediate cut

Replace the Power cord

4 Keyboard error message displayed when system is switched ON

Any keys in the Keyboard may be in pressed condition

Switch OFF the system and release the struck keys and again switch it ON

Keyboard may be defective Replace with any other PS/2 or USB type keyboard or get it solved by Service Engineer

5

Camera obstruction error signal displayed at Turn left / right screen(NV / MS error)

May be due to dust particle deposition in Camera‟s dust prevention glass. External Sun light reflection/ Stone guard self reflection

Clean the dust with a soft cloth

Enable the multiple spot program in the settings option.

If the problem is still not solved by cleaning the Dust prevention glass

Camera path may be obstructed due to Low body vehicles or due to any reflection

Spoiler program can be used to overcome this problem

Ref.: CCDWA - OM 89

Sl. No.


The problem still persists even by using Spoiler program up to 3.5° down

IR LED (Light) just above the camera may not be working. Not Enabled the multiple spot program in the setting option.

Battery voltage may be low. Recharge the Sensor arms by placing it in the Charging tray or get it solved through Service Engineer

6 At straight ahead position, Unable to match the ball.

Arms Horizontal may got disturbed

Correct the Arms horizontal and to zero level.

May be due to any reflection from the vehicle body

Select spoiler program and complete the alignment

7

During Alignment camera obstruction signal was noticed intermediately

May be due to any external light source affecting the Rear camera operation

Block the external light source to solve the problem.

Enable the multiple spot program in the settings option.

May be due to dust deposition in Rear camera‟s Dust prevention glass

Clear the obstruction by cleaning it with a soft cloth

8

Low Battery indication always displayed

Sensor arms may not be located properly on the Charging tray

Once again rest the Sensor arms properly on Charging tray and ensure that the Charging LED (Yellow) is ON. After complete recharging of battery, redo the alignment process

The problem persists even after complete charging

May be due to any technical problem in the Sensor arms internal circuit

Get the problem solved by Service Engineer

9

Always fast discharging takes place in any one of the Sensor arm battery.

Problem may be in Charging tray

In alignment screen press CTRL+V to view the charge level. If the level is found to be week, place the sensor arm straight to the charging tray.

Battery may be defective Replace the battery with same specification

Battery charge level, for all Sensor arms found to be OK. But still problem remains unsolved

May be due to week signal strength

Shift the Sensor arm to the next Charging tray and allow it to charge for 4 hours. If problem is not solved, get it solved by Service Engineer

10

Autoretrieving data from/Timeout error (FLA, FRA, RLA, RRA)

Sensor arm fuse holder may be having loose contact

Tighten Fuse holder manually. Also, once the Sensor arms are lifted from the Charging tray ensure the Green LED is ON

Sensor arm may not get charged properly. Check whether battery low status LED is on.

RF Transceiver / USB having loose contact in the interface box

Due to power failure or improper fixing of arms in Charging tray, over night charging may not happen. Recharge it again

Fix these connectors firmly.

Still the Autoretrieving data / Timeout error occurs intermediately

External RF interference

Hi powered Wi Fi signal presence

Check for high powerful 2.4GHz RF transmitter near by area

Ref.: CCDWA - OM 90

Sl. No.


Same RF channel used wheel aligner presence in within the area of 100meters

RF transceiver and sensor arm is not in line of site

Technical problems in Internal circuit boards

Change the RF channel above 10 in the wheel aligner.

Avoid too much of metal obstruction between the RF Transceiver and sensor Arms

.Get the problem solved by Service Engineer

11 Multimedia speaker not working

Input supply to speaker may be disconnected

Remove the plug point and re-fix it properly and ensure that the Green light in the Speaker is switched ON

Audio output connection from Motherboard may be disconnected

Ensure that the Audio output is connected to the Green color of Motherboard. Remove and re-fix it again

Multimedia Speaker may be defective

Replace the Speaker

INTERFACE BOX

Sl. No.


1

All the battery charging LEDs in the sensor arm are not glowing when putting in to the charging tray No AC output power for the PC/Monitor

EMI Filter board faulty

Check physically for any loose contact / damages in wire. If found replace the wiring Check & ensure the Filter board is not burnt Check the input supply voltage (230VAC) at the I/P section of EMI Filter board Check the output supply voltage (230VAC) at the O/P section Replace the EMI Filter board

2 RF Transceiver unit disconnected

SMPS faulty

Check physically for any loose contact / damages in wire. If found replace the wiring Check the input supply voltage (230VAC) at I/P section of SMPS Check the output supply voltage (12VAC) at the O/P section Replace the SMPS

DESKTOP COMPUTER & PERIPHERALS

Sl. No.


1 Not Powering ON

Power cord may not be connected properly or may be defective

Ensure proper connection or replace it

Faulty SMPS Check for output voltages. If not OK, then replace the SMPS

Power switch may not be functioning properly

Check and correct / replace it

Power Connector is not connected to the Board

Check and connect it

Ref.: CCDWA - OM 91

Sl. No.


2 Booting Problems

RAM not fixed properly / loose in the slot

This problem in Indicated by beep sound for a duration of 1-2 seconds. If so check whether the RAM module is firmly fixed into the slot

Faulty RAM module Replace the RAM

Faulty Mother board Replace the Mother board

3 No Display

Faulty SMPS Check for output voltages. If not OK, then replace the SMPS

Loose VGA connector Check whether the VGA connector is connected properly. If not connect it firmly

Monitor not switched ON Switch ON the Monitor

SDRAM not fixed properly / loose on the slot

Insert the SDRAM firmly into the slot

CMOS setup corrupted

Switch OFF the system and clear the BIOS by changing the position of the CMOS jumper to “Clear CMOS” by referring to the Manual. After clearing the CMOS on the system, power ON the system and go to CMOS setup and detect the Compact Flash / Boot Device in the BIOS

Faulty Mother board Replace the Mother board

4 Keyboard not detected Loose Keyboard connector

Connect the Keyboard connector firmly

Faulty Keyboard / cable Replace the Keyboard

5 System hangs up

Processor over heated

Check whether hanging is observed after specific duration from power ON and whether the Heat Sink is getting heated on the Processor or the Co-processor. Check the cooling fans are running in good condition

Faulty peripherals

If the system halts at a specific point during Boot up, check for the specific peripherals and correct it

5 System hangs up OS / application software corrupted

If the hanging is observed when booted to the OS and running the application, check whether the application or the OS has got corrupted. If so, reinstall the software

6 CMOS Checksum Error Faulty CMOS battery

Check for CMOS battery voltage. It should always read +3V. If not, replace the Battery

Ref.: CCDWA - OM 92

Sl. No.


7 Non-System Disk or Disk boot failure

Hard Disk Drive(HDD) not detected

Insert the cables into its cable slot

HDD become defective

Check whether the HDD is detected in BIOS. (In BIOS, detect for HDD). If not detected, replace the HDD. If the BIOS detects the HDD, check whether there is a Disk Partition and whether it is formatted or due to booting file corruption

9.2. SOFTWARE TROUBLE SHOOTING

Sl. No.


1 RUN TIME ERROR „9‟: Subscript out of range

RF interference of two Aligners at the same location

Shift one Aligner to a different location out of RF range

Existence of same RF channel No / frequency (of similar or different devices)

Change the RF channel number in the Aligner

2 RF Transceiver not connected

Fuse may be defective in Interface box

Replace the Fuse located in the Interface box

EMI Filter board may be defective

Replace the EMI Filter board

SMPS may be defective Replace the SMPS

No power supply to RF Transceiver unit

USB port may be unplugged from PC

USB port cable may be defective

Replace the USB port cable

USB port may be disabled in OS settings

Enable the USB port via device manager option

USB software may not be installed

Install the USB driver software.

Personality board may be defective

Replace the Personality board

USB port section may be defective In PC Mother board

Check the USB port option. If not working, replace Mother board

3

Error-1 RF Transceiver unit connectivity disturbed during alignment

RF Transceiver unit in unplugged / loose condition or loose contact in it's connector

Ensure the connection is secure and also tighten the BSM connector

4 No Video (NV) (common for all Sensor arms)

Respective IR Led may not be working

Check the supply to IR Led across connection

Obstruction between IR LED & Camera

Remove the obstruction

Dust particles Dust prevention glass

Clean the glass with soft cloth or tissue paper

Zero Camera dia count in Camera setting

Mount all Sensor arms in Calibration kit and ensure Dia value as tabulated in Chapter 8.4 of Service manual

Faded IR Filter Replace IR Filter

Problem in Arm board Replace Arm board

Problem in Camera Replace Camera

Ref.: CCDWA - OM 93

Sl. No.


5

Multi-spot (MS ) (common for all Sensor arms)

External light/reflection on the Camera

Prevent external light falling on the Camera

Camera Dia disturbed

Mount all Sensor arms in Calibration kit and ensure Dia value as tabulated in Chapter 8.4 of Service manual

Faded IR Filter Replace IR Filter

Faulty Camera Replace Camera

6 No Vertical Sync (NVS) (common for all Sensor arms)

No power supply (+5V) to Camera

Ensure +5V power supply to Camera connector

Loose connection in Camera connector

If required, solder the Camera connector directly

Camera may be faulty Replace the Camera

Defective Arm board Interchange the Arm board from other Sensor arm & conform

9.3. SELF DIAGNOSIS Following message box will be displayed in case of any fault identified during alignment sequence.

To diagnose the exact root cause, click “Click here for Error diagnosis” button and the system will diagnose the error. User will be advised to wait for few minutes and DO NOT disturb the system during self diagnosis.

Sl. No.

Error Causes Remedies

1

USB cable may be disconnected from PC

Ensure the proper USB connectivity

RF Transceiver unit cable disconnected

Ensure the proper 4Pin BSM connectivity

Fuse (F1) may be blown in Interface box

Replace the Fuse with correct rating

No power supply to RF Transceiver unit

Check the Power LED glows in RF Transceiver unit. If not, contact Service technician

2

No supply to the Charging tray

Check 12V supply in the respective Charging pins in Tray. If not, check & ensure the Charger connectors (2Pin) are connected to the Interface box properly (ref. Sl.No.11 of Fig.26)

Battery voltage is <5.4VDC

Charge Battery for 8 hours (min.)

Failure in battery charging

Check the Battery voltage/ connections after 8 hours of charging. If battery voltage is below 6VDC. Replace the Battery

3

Sensor arms are in switched OFF condition in charging tray

Remove from Charging tray and switch on the Sensor arm

Ref.: CCDWA - OM 94

Sl. No.

Error Causes Remedies

Sensor arm fuse holder loose (no power to Sensor arm)

Tighten the Fuse on the Sensor arm, so that power is supplied to Sensor arm

Defective fuse If Fuse is found to be defective, replace the Fuse with correct rating

Battery drained out in the Sensor arm

Place the particular Sensor arm in Charging tray/connect cable

Same Arm board ID programmed wrongly in two Sensor arms (two sensors arms having same ID)

Connect only one Sensor arm at a time to the Interface box and select the required arm board ID

Different RF Channel Nos. in RF Transceiver unit and Sensor arms

Ensure that all the channel numbers are same in Sensor arms & RF Transceiver unit

Defective RF Transceiver board

Contact Service technician

Defective Arm board Contact Service technician

4

RF Channel settings are not same across the Sensor arms & RF Transceiver unit

Ensure that all the channel numbers are same in Sensor arms & RF Transceiver unit

Same RF channel used in nearby RF aligner within 100ft distance of same premise

Ensure the Channel numbers are set differently for both the RF Aligners. Same channel numbers should not be used in same premise

9.4. MIS-ALIGNMENT TROUBLE SHOOTING

Sl. No.


1 Car pulling towards one side

Misaligned Rear axle (ie., unequal Rear Toe). Rear axle is not perpendicular to Geometric Centre Line

Check the Rear suspension for worn out control arm bushings or sagged springs

Setback Check the position of the Front wheels are in line

Improper Camber setting. Car pulls sideway with more positive Camber

Check for worn out ball joints or control arm bushings and sagged or broken springs

Uneven tyre pressure. Car pulls sideway with low inflation

Check both tyres are with same pressure

Mismatched tyre sizes. Steering pull due to mixing of Radial & Normal tyres and cross ply

Both Front tyres must be of same size, same design & should have approx. same amount of thread wear

Incorrect Caster setting Caster must be same on Front wheels Check for worn out Control arm worn strut rod bushings

Dragging brakes and car pulls sideway

Check for corroded brake caliper piston and misadjusted emergency brake cable

Ref.: CCDWA - OM 95

Sl. No.


Power steering problem

Check for uneven Steering balance of Front wheels in jacked up condition and run the engine. The steering should not turn one side due to leak in Control valve. The steering effort should also be equal in both directions

Steering problem with tyre Check for faulty tyre construction

2 Car wanders

Loose steering parts Inspect Tie rod ends, Idler arm and steering gear mountings

Worn out steering gear Adjust if possible. Else replace it

Vehicle skids while applying brake

Check for worn out strut or Control arm bushings

Loose Wheel bearings Remove the loose bearing and inspect for damages. If so, replace it

3

Tilt in Steering wheel even after alignment

Toe not adjusted equally Make the length of Tie rods equal

Misaligned Rear axle Check the rear axle alignment, worn out Rear axle mountings, Sagging springs or collision damage

1. If “Runout Compensation” skipped.

2. If “Ride Height” Value skipped.

3. After Caster adjustment, Redo process not carried out

1. Runout compensation to be done compulsorily

2. “Ride Height” Value should be entered 3. After Caster adjustment Redo process

should be carried out compulsorily

3

Tilt in Steering wheel even after alignment

Wheel bracket not fixed properly

1. Ensure wheel bracket rim locking pins are clamped properly

2. All the Wheel brackets should be clamped uniformly either at inner or outer side of Rim

Ensure the wheel bracket is fixed on the rim at 12 o clock position (While the wheel bracket center block is slide down).

Wheel bracket may be defective

1. If Screw rod is found to be bent, replace the Wheel bracket

2. Fix all the Wheel brackets one by one in another Wheel rim and ensure the bracket motion is proper. If not, replace the particular Wheel bracket

3. Fix all the Wheel brackets in a particular wheel one by one and ensure the readings are similar

Uneven pit level

1. Pit must be leveled properly within the tolerance of ±2mm

2. Zero level should be ensured diagonally (ie., between Front Left & Rear Right and Front Right & Rear Left) without deviation

4 Other symptoms

Tyre wear on outside shoulder due to excessive positive Camber

Inflate the tyre to recommended pressure and adjust the Camber as per the specifications

Tyre wear on inside shoulder due to excessive negative Camber

Inflate the tyre to recommended pressure and adjust the Camber as per the specifications

Tyre wear on both shoulders due to under inflated tyres

Check the tyre pressure is as per recommended specifications

Saw tooth tyre wear due to too much of Toe-in or Toe-out

Adjust the Toe as per specifications

Ref.: CCDWA - OM 96

Sl. No.


Abnormal tyre wear due to loose Steering system, misaligned Front or Rear wheels, defective suspension system or car is overloaded

Correct the Steering system, align Front & Rear wheels and correct the suspension system. If necessary replace the parts

Hard steering due to low or uneven Tyre pressure, more positive Caster or tight Steering system or defective Power steering

Check & inflate the tyre as per recommended pressure and adjust the Steering system or replace the Power steering

Tyre squeal on turns due to wrong Toe Out on Turn angle from misaligned Tie rod, or bent Steering arm. Low or uneven tyre inflation

Align the Tie rod and adjust the Lock angle and check the tyre pressure

Unstable at high Speed due to incorrect Front or Rear Toe or worn out steering components

Adjust the Toe or replace the worn out steering components

Manufactured by

All rights reserved. Any reproductions of this document, partial or complete, are not allowed without prior consent of Manufacturer All information, illustrations and specifications contained in this Manual are based on the latest information available at the time of publication. Manufacturer reserves the right to make changes at any time without further notice to any of its products to improve reliability, functions, design or whatever can be thought suitable

C__WHEELALIGNER_CCDWA - OM Ver.1.2.pdf

Documents

wheel runout

wheel alignment computer

wheel alignment parameters

wheel aligners

scope of supply

computerised wheel aligner

rear wheel slider

rear wheel setback